26/06/2011

Alignment

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ALIGNMENT

There are two types of alignment methods: Face and perif Reverse alignment Reverse alignment is the most ac curate method, but should be used in conjunc tion with Face and Perif method. Face and Perif method: vertical Alignment (Angular)

Fixed machine

D1 F1

Machine to be moved Fig. 1 F2

D2 D3 F1=First hold down bolt F2=Second hold down bolt D1=Diameter of the circle made by dial indicator tip when coupling of the fixed mac hine is rotated 360 deg. (mm) D2=Distance from Pointer of dial indicator to first holding down bolt F1.(mm) D3=Distance from pointer of dial indicator to sec ond holding down bolt F2. (mm)

Always align angular misalignment first in both vertical and horizontal alignment. For vertic al alignment, zero dial ind T.D.C .Rotate through 180 and note total indicator reading (T.I.R) and sign. To calculate the amount of shims req under F1 and F2, following method can be used Ratio between D1 & D2,D1 & D3 are required. Example Say: D1 = 50mm D2 = 100mm D3 = 200mm

R1=100 /50=2

and R2=200/50=4

If dial indicator reading = +0.2mm Then distance between coupling faces are greater at the top than bottom Add 0.2 X 2= 0.4mm at F1 0.2X 4 =0.8mm at F2 When T.I.R = o.1 or less check for height alignment, as per the fig 2

Fixed machine

Machine to be moved F1 F2

Fig. 2

Once angular alignment has been achieved, equal amounts of shims can be removed or added as calculated below indicator at T.D.C .Rotate through 180 and note total indic ator reading (T.I.R) and sign. For a minus dial indic ator ,add shims under m/c to be moved equal to that of the indicator reading. For a plus indic ator reading remove shims machine to be moved equal to that of the indicator reading.

HORIZANTAL ALIGNMENT(ANGULAR) Three dial indic ators are required. Positions are shown in fig 3

F1 Fixed machine D1 F1

F2

Machine to be moved F2 Fig. 3

D2 Method D3

Zero dial indicators (D.I) and rotate through 180.Note the reading and sign minus or plus. Using fig. 1 find ratio R1 R2,c alculate distances to move m/c at D2 and D3 . Zero dial indicators positioned at feet of m/c to be moved and move machine until indic ators read calculated dimen T.I.R = 0.1mm or less, horizontal alignment can be c hec ked. Positions D.I as shown in Fig 3 .Zero DI and rotate th 180.Note indicat or eading and sign. Zero D.I position at feet of m/c to be moved and mov machine until both D.I indic ate error previously recorded.

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Alignment

(2) REVERSE ALIGNMENT D1 A

Fixed machine F1 B D2

Machine to be moved F2 Fig. 4

D3 P A=clock dial indicator on coupling hub (fixed m/c) B=clock dial indic ator on Coupling hub (mac hine to be removed) F1=First holding down bolt F2=Second holding down bolt D1=Distance between dial indicators D2=Distance from p to first holding down bolt D3=Distance from P to second holding down bolt Before starting the alignment, an alignment Graph must be made-see attached graph 1 Install clock dial indic ators as in Fig 4 2 With Marker pen mark of the positions of dial indicators on the coupling hubs. METHODS FOR VERTICAL ALIGNMET Always stand with the fixed m/c on your left hand side, and m/c to be moved on your right hand side.

(1) Position the dial indicators as shown in the fig 4. with the A dial on the top of the Fixed m/c coupling hub, and Dial indic ator at the bottom of the m/c to be moved. (2) Set the indicator to zero and turn both coupling hubs through 180.Note the T.I.R of the A dial indicator and reading was plus or minus. (3) Set the B dial indic ator to the top and turn both coupling hubs through 180.The B dial will now be back at of the hub. Note the T.I.R of the B dial indicator and if the reading was plus or minus PLOTTING READINGS ONTO GRAPH A 0.2 0.14 0.05 0,0 0.15 D1 D2 D3 Subtract shim =0.05 mm Add shim = 0.15 B F1 F2

A= + 0.4 /2 =0.2 B= 0.28/2 =0.1 Reverse sign

Example: A dial reading of +0.4 mm T.I.R B dial reading of -0.28mm T.I.R On the A line of the graph, plot half the T.I.R of the A dial indic ator to pre-determined scale. As the reading was mark has to go above the pump center line.

On the B line of the graph, plot half the T.I.R of the B dial indicator to the same scale ,but in this case you mus the sign. In the Example from minus to plus This is very Important. Plot point on graph above center line.

Note:If the reading B dial was plus, reverse sign to minus. Plot point below c enter line of graph. Place a straight edge through the two points and draw a straight line passing through points F1 and F2.Te distance center line to the plotted line will be the amount of shims to be added or subtrac ted from F1 and F2 respectively. I plotted line is above the center line, subtract shimsand below add shims. HORIZONTAL READINGS

A F1 F2 Machine to be moved F1 B F2 Fig. 5

Fixed machine

Horizontal readings are taken the same way as for vertic al readings. Only the dial indicators are set in plan view.

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Alignment

In the horizontal position the m/c to be moved is physically moved on the base frame, as shown in Fig 5.Plac ing dia indicators at the feet of the m/c to be moved, move m/c in acc ordance with plotted graph. Ensure that you are m in the correct direction. Make a note on the graph whic h way a minus or plus has to be moved in the horizontal po Away or Towards you.

Please note the following rules: (1) Always c hec k that you have the correc t distance between coupling ends. (2) When aligning Multistage Centrifugal pumps, fill pump casing with water push pump shaft into pump body to sep plate fac es. This is very important as the wear plate fac es can pick up if this is not done. (3) Always rotate both couplings together to eliminate coupling run out. MORE

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