POM PROFESSIONAL TEC RIU & NGINEERING @ Also covers alignment of bearings, gears, pulleys, & more Machinery Vibration | ALIGNMENT Vietor Wowknn —— Contents McGraw-Hill 2 A Dien of The McGraw Compan Boo = ‘The sponsoring editor for this book eas Linda Ludwig the prc — Yereeeeenect lon tuperisor sear Sherr Soufrance This book was set in Century ioe Printed and bound by RR. Donnelley & Sons Compan. 1 i i a f < 8888 2 Jagaceseey BSPre-Allgnment Checks a the Machine ~ ort shat a Casing Distortion a7 (Chapter 5. Rough Method * ‘Bar5a9 a Mechanics! Changes 2s Chapter 6. Reverse indicator a Piping Strain i Thrust Forces Fr] ‘Setups Fa Torques im Prinipion 100 Hydra Forces ea ‘Advantages and Limitations 106 ‘Shaft Ring Up onthe OF Wedge in Mathersaticel Formulae 05 Gear Reactions fa Graphical Pioting a7 ‘Thermal Growth ea Protting Exam Pee 100 Field Measurements of Growth Fed Varations 1” ‘ial ineator 20 Proximity Probes Mounted on Wate-Cooled Stands 28 ‘Chapter 7. Face and 19 Benchmark Gages ES Doda Bare a Setup 10 {natrumented Coupling a Theory 0 Optical Measurement ey Calculations = Laeery me Example Problem 136 Verner Strobe za Variations Py Hot Alignment Za ‘Comparison of Methods 0 Grow Compensation z ‘Chapter 8. Moving Machines 1 eee is Toole oy ‘Gaining Access ue ‘Straight Line Methods zo Meesurement| “s Fim Method. mo Calculation w FocoFece ze Movement 0 ‘Shaft Sag 22 Prepare to Opera 1% um Sen, 2s Procedure 10 ‘Axial Postion ing 1s (Chapter 12 Large, Heavy, or Multiple Machines or erica! Moves = Hertzontal Moves = tnt Placement Pa Strategy 165 Natura Sap Curve m Moving While Opera 13 ay (Chapter 13. Flange-Mounted Equipment as CChopter 8. Alignment Tolerances m (Chapter 14. Single-Bearing Machines 2 Metrology 1m Coupling Tolerances 8 Close-Coupied Equipment a How Long Should Algnmen Take? 77 When to Stop 7 (Chapter 15. Reciprocating Machines m ‘Bearing Siiness and Vibration 1 Foundation Sttiness ee Chapter 10. Complicating Factors, ry ‘Alonment Onsts and Heat KY co mm Nonrepestable Measurements 134 Poor Foundations 8 (Chapter 16. Component Alignment om ‘Symptoms of Resonance, 9 ‘Teats{or Resonance rs Bearing Alignment 5 Fixes or Resonance: 0 Setv-Algning Bearings i} Case History ofa Diesel Engine witha Base Resonance a Alignment Fjvil Contents Pulley Alignment chapter 17. OpicelTooting Intruments Methods (Chapter 18. Laser Alignment “Technology of Laser ‘Advantages and Disadvantages Chapter 19. Couplings Purpose and Theory ‘Types of Couplings Rigid Cylinder Contoured Diaphragm ‘Siiging Block and Stding Olek Rotating Link Carden Joints Elastomerle Compression Elaatomerle Shear Fluid Couplings: Magnetic Coupling ‘Selection Criteria ‘Appendix A. Alignment Toots and Supplies ‘Appendix B. Drawings ‘Appendix C. Formulas ‘Appendix D. Alignment Standard for New and Rebuilt Equipment Bibtiogrephy 373 dex” 377 2888 8 @ 8 € & ELESAeRRRRAAeeesEseeeeeA AE ee Preface public and yament courses during ‘ments and additions from the students. provide practical knowledge to the hands ‘Over the years, exch alignment job in the field tions, Notes were taken and colleagues were consulted. The meth twere modified and added to the original manuscript. More import ‘Machinery Vibration: Measurement and Analysis Machinery Vibration: Balancing ‘A fourth book dealing with resonance and isolation is partially complete and is expected to be published in the future. Victor Wowk Albuquerque New MexicoAcknowledgments ‘This book is the handiwork of more than one person. The following people have fingerprints embedded in this work through that first alignment job the alignment fixture ignment field with prod- ly provided photographs orChapter . Introduction the most valuable too! to approach pr provide alignment knowledge. book also serves as a reference for the generat Vibration of machines. The chapters are in discrete topics. Any chapter can be rea tion was to provide a source to which the ines the concept and pro nology. yanize the need for alignment from other indicators2 Chapter One a general discussion of geometric characteristics and metrology (ihe selence of measurement) and how they relate to machines. Dial indie ‘and optical instrument tion prevents us ‘Chapters 6 and 7 are the the standard setups. chapters in the book. They cover in detail the reverse-indicator and ‘rim methods of alignment. The theories are discussed, and example prot ‘presented. The variations of these two are sno are also included. The end of Chapter 7 contains a comparison of these Tio major methods to help the reader decide which one 0 use. “Chater 8 describes the ols andthe process of actually positioning machines safely and precisely. ‘Chapter 9 answers the important question of tolerances: How enough, and when does one stop? ‘Chapter 10 contains information on how to handle the diffi chapter should be referred to when vibration remains after & has been performed. good machines or configura , flange-mounted equip- ptcal tooling. Optics isthe most general, most universal ‘cases the only way to measure the relative orientation of two strument—the laser -to-shaft align ‘other alignment “The Appendix contains the bibliography, @ lst of suppliers. some ena drawings of alignment fixture parts, formulas, and a generic alignment s Iewroduetion 3 gure 14 A diver an sven machine comecied with a semieible coupling What Is Alignment? [Alignment is generally thought of as shaft-to-shaft alignment of coupled ma- ‘driven machine. The driven machine produces [power or moving Muids, and could be a generator, wachine provides the rotating mechanical power to nan electric motor, but presumed to be the one ‘and the least amount of ‘The goal of alignment isthe proper orientation of mechanical parts, whatever4 Chapter One proper means. The purpose for doing alignment is ‘caused by dynamic forces. Dynamic forces are mes ing ines coaxial under operating conditions is a good starting point. Other power ‘components, like gears and bearings, may funct nt. Finally, mechanical components themselves are not perfect, 10 work with non- different measuring an inexpensi id meter. The measurement parameter, however, should be Figure 23 Vibration 400. poms. Pump (o) is misaligned and in acceleration to maximize the high-frequency contribution of the harmonics. ssovtig. Por more gutMISALIGNMENT, MLS. = OFFSET ar REAR FEET + OFFOET At Figure 22 Overall acceler Nave tht the ost at the font Targerelfct on vibetion. overall of the energy in the harm« the fundamental vibration at 1X rpm is Diagnosing Misalignment 21 ing more random, Same frequency range as shock pulses. Many bearing analyzers can quantify these Shock pulses. They can be viewed directly on a digital storage oscilloscope with fan accelerometer as the signal input transducer. Figures 2.5 and 2.6 show shock ‘Rowe 24. Total harmonic distortion vers horizontal misalignment. Offs a the fon feet fenerte moce vibration, Phe Figur 25 Shock pues in rough al bearing, The Sensor used was a 10D Vis fecelerometer, x0 the verucal scales #50SAAT Figure 27 Misalignment forces ause some ska motion because of th ne sided oundation edowns, misalignment is high axial vibration. The forces at direction, and it also must move upward against gravity. Most of the oscillatory Diagnosing Misalignment 23 energy is directed horizontally and some axially. When the axial vibration be- ‘misalignment is suspected. Large is defined as > one-half ofthe hori- furthest from the foundation. Misalignment Versus Unbalance ‘The vibration symptoms of misalignment can be similar to unbalance. For linear 2" systems, there may be little harmonics from misali but Tigh 1X spe Low axial vibration “Temperature independent —— Balancing and alignment are the two most common corrective fixes for vibra- ‘which is dominant in a specific case. Alignment can be do balance does not affect the alignment process. Alignment can be accurately per- lance by shifting the product of inertia. first when stopped, then balance. However, this gen- ‘weight and obtain some new vibration measurements. The appropriate question is,24 Chapter Two “Which is easier to do at the moment on the machine at hand?” Installing couplings is part of the alignment process. The aligner should realize axial motion, withthe added load. “Angular misalignment creates a torsion: 3s nullifies this variation in speed effect. Common de- signs are vehicle drive jth two universal joints, spools with two couplings, ‘of double engagement couplings. TENSION Figure 28. Angular misalignment creates «torsional xciltion. Chapter 3 Measuring Misalignment ‘Alignment is process of measuring something, comparing to-a re dard, making adjustments, then remeasuring. The key element of ‘measurements. This chapter describes the instruments and meth Jevel of the instruments used." Alignment is a feature that has ‘of 2er0 and does not lose physical existence when approaching zero. Compare a0 ‘weight is not measurable because there are no forces gardless of how much resolution the spring scale has. 1g deflection, Alignment, by contrast, geometry if we are to avoid chasing a crooked line. Metrology . Mechanical measurements on machined parts are very as some other fields. Table 3.1 provides some perspectiv but not as precise:+ 1,000 feet +60 inches £ 0.1 inch (1/8 inch) 0.001 £0,000 04 (1 micron) determine accuracy to one mil le gauges, dial indicators, and feeler ) generally requires that Measuring Misalignment 27 ‘nest important requirement of any easement ischancterzed tse ca ie 1g the mean value and standard devia- Value but rater the artimetic average measure ofthe spread ofthe caster The recive the measuring sytem. Figue 3.2 eet. A inaccurate meacarement has lage uncertainty.‘gure 22. Pression is 4 caracteritc ofthe spread of a roup of measurements neering Drawings.” After each def lity to alignment igularity: The condition where one plane or line is oriented at an angle from appli lar Runout: The coms rotated through 360°, Measuring Misalignment 29 “This is measured with a dial indicator on the surface ofa shaft a is a combination of nonroundness, bend in the shaft, and bearings a constant rotating center, + Coaxial: This exists when two or more feature ‘Achieving closer coaxiality is the purpose of shat + Concentric: A condition in which two of more featur hexagons, etc.) have a common axis. ©) S o Figure 24 («) Concentric bre ina coupling hal (2) bore not concentric with outside dametr. ide diameter. A dial measure no devia should be concentric with the {ated around this stationary coupling will show a large deflection «90 Chapter Three are perfectly aligned. This problem is one pitfall in rim measurements, It can be avoided if both shafts are rotated together. Gears, pulleys, and sprockets also need to have concentric bores. The inside Rotors that operate with a clearance to thei ‘and compressors, do not need to be concent not rub. They can be mass-balanced to run stator windings that are I generate an clecromagnetic force ing OF slip, and interfer- 1g oF imerference fit. Clearance ly poorer operation with vibra- Figure 35 Eeceiiciy created by a bent shaft, Measuring Misalignment 31 lowe 36 ites SS ‘gure 37° Offi pull splacement between shaft centres, fa surface having all elements in one plane. <7 entation in space, Machine bases need to be planar, machine feet, Fig. 3.6. They do not need to be parallel with the earth's face nor parallel with the machine shaft. wwement (FIM): The international term for total indicator move- ‘ment (TIM). + Horizontal: Perpendicular to + Level: 90° to an earth radian; same elevation, Alternately, ‘Level says nothing about straightness or flatness. The two highest points of a line oF three highest points of a pl Machines generally do not need tobe I con its side, upside d required are when sensing devices are on board. + Offset: The distance that one The distance between t 3 contains points all at the the top surface of fluid in a con- the displacement ata specific posi- gts length «aa ing a p s t teey oi Line o plans dot intersect, Fig. 38.7«= Perpendicular. Being at 90° to each other, Fig. 39. Parallel and perpendicular always refer tothe relationship of two or more fea- turing technology machines holes y. A nonperpendicular coupling half introduces an ‘problem i if both shafts are rotated together the dial indicator tip remains parked on the same ies during horizontal moves. ‘arrangement of parts defined by distance, location, or angle. 'sa relative measurement of one part to another. face: The mapping of the position of all points of a surface in a Tine passing through the center ofthe earth. + Radian: A st ‘Plumb and level are important only for machines with liquid tanks and gravity sensors, ¢-g., pendulums. igure 38 Pari Moasuring Misalignment 33 al average of many measurements because the eccentricity circle may the same path with each rotation. ig. 3.11 defines the rotational center with examples. This shaft that we really want (o align to. It s the same as the shaft a straightness and perfect bearings. The reverse-indicator method rotational center, regardless of any shaft, coupling, or bearing imperfections.34 Chapter Three * Runout: The composite deviation of a circular part during one full rotat 360°. 7 7 ‘This‘is easily measured with a dial indicator, Fig. 3.12. I is @ combination of is characterized by a high spot nearly from the horizontal Concrete almost always has a slope for drainage purposes. This needs to be adjusted for on machines that require being level. +. algorithm for positioning machi * Total Reading (TLR.): The f ‘maximum negative fo maximum the is taken during one Tull revolution or during. shape. sé i, and bearings either determines their alignment lack of perfeet geometric form. This failure to distin- sntis one of the most confounding challenges to align- R. of shafts, ‘uish geometry from align ‘ment Ve cal: Inthe direction of gravity. At right angles to the horizontal 1 and horizontal are the usual directions chosen to move machines, mostly for convenience. This, then, defines the planes onto which to project the readings. ator is @ precision mechanism for displaying the small movement of a cor Imposed of a case for mounting the parts, a spindle with a ‘contact point and amplifying mechanism, a pointer, and a graduated dial, Fig 3.13. ‘They also have an outer bezel that rotates the graduated scale, allowing zero to be lined up anywhere. The amplifying mechanism is a precision rack-and-pinion gear operated relative displacement gage. The case is “The movement of the contact point in the cease is the displacement of interes “The dial indicat direction of the spindle relt 36 Chapter Throe Measuring Misalignment 37 ‘The AGD and backplunger jgnment work. They have without hitting the of typically .015 to space is cramped. It 1. The face of the indicator can be numbered from 0 to 100, the ‘continuous reading scale, or from +.050 and -050, the balanced reading scale. in Fig, 3.15, indicators read -.015 inch. The bal- erving the sign in addition to the number. The only observing the number and is recommended (@) ses the pointer to tum clockwise, or dial indicators, metric or English he pointer turns counterclockwise, or negative. This is iment work because the dial ‘A person who | indicator may be viewed upsi understands this simp! tions from the raw dial indicator readings. Pure 315 © fraated in reading PeMeasuring Misalignment 38 indicator reading is 0.050, but the parallel offset is one half ofthis amount, or 025 inch. Measuring Rotating Shafts Misalignment has been traditionally measured with precision mechanical instru~ ments found in a machine shop. These instruments are straight edges, levels, thick- 1d dial indicators, and are stil very useful. The very TI ste moves mn ‘ollinear, Fig. 3.17. We need to assume that the two shafts are straight and of the Same diameter and round in the two planes where measurements are taken. This ‘method could workin the field to align a pump toa wwe had flat reference ly are such good reference surface: inward and the pointer reads the 6 o'clock position, the stem moves out and the needle"The face-and-rim setup is shown in sets of measurements —one on the coupling half or bracket, agai ie coupling remains attached and ing could be di IY one clamp would be required, in that ca face-and-rim method is based on the plane of the dial-indicator sweep. ‘pecify the angle. The two measurements then define the ton to the shaft that the indicators are fixtured ‘center of the shafts. Coup! are not a factor. The reverse-indicator setup is two separate rim measurements, The term “re- mn. Historically, the face-and-rim method ‘clamp, the clamp had to be re-fixtured. The measurement was ne shaft tothe other, The clamp was then disassembled and the clamp Measuring Misalignment 41ig centers are measured di yme alignment situations, and in some ca isthe only method that can be used. Figure 3.19 shows some other commercially available alignment fixtures. No outstanding advantage over oth ical alignment tasks. in adapting to small spaces, 1. Rigidity 2, Ruggedness to survive in an abusive, dirty, mechanical environment. Specifi- Should be shock-resistant when dropped, or when tools are dropped on 3. Ability to be used on many different machines. Shaft sizes vary, different dis tances need to be spanned, and there could be clearance restrictions. 4, Ability to convert to face-and-rim measurement. There are cases where one shaft cannot be rotated like gearboxes). In these situations a face-and-rim setup is more practical 5. Ability to handle drive shafts with two widely separated couplings. Figure 3.20 ‘shows a rim-rim reading setup on a long drive shaft. may not be sufficient to handl these requirements. Two or fixtures with enough accessori catalogs. The most diffcu -an be made from bracket materials o use existing threaded Measuring Misalignment 43Measuring Misalignment 45 44° Chapter Three sirface, Fig. 3.21. This eliminates cosine errors due tothe angle. The dial indicator ~~~ deflects only the amount of travel along stem. The dial indicator is set at cycle shift ar rigidity of the measurement system. A non-tetum to zero within 1 mil after the second 360° rotation means that the t00 flimsy. The clamp system needs to be rigidized, Go around and re ‘but not necessary, fo It is necessary, howev orface af» machine fot A ts age sorta: Figure 321 The on a curved surface, (a) reading 0048 Chapter Three for range exceedances of the indicator. Lib ‘move as the shaft is rotated, something is the tip is not touching. “The principle of continuity requires that the measurement deviations form a ‘around onto itself. For align- ‘ment, this means that the algebraic sum of the top and bottom readings must equal the algebraic sum of the two side readings. This is called the validity check and is. illustrated in Fig. 3.23. The sum of top and bottom readings is 0-17 = -17. The '=-17. Therefore, the readings are valid. If imply states thatthe sum of the two side ing. to move laterally within the clearance, and ‘may not be consistent, or valid. The shaft may need to be stabilized temporary shims in the bearing to achieve repetitive readings. The ‘sum should deviate no more than about 5 percent of the largest ling. A gross error in the validity check indicates that: 1. The dials were misread. Most often the signs are misread. 2. The indicator tg lost contact with ts target at one measurement position, or bottomed out 3, The indicators were bumped sometime during the process and lost zero. 4, The dial indicator is stuck. r Measuring Misalignment 47 ‘5. The bracket is loose. 66, The misalignment is so bad that the coupling binds and the readings are not ‘continuous. “The validity check requires combining numbers of different signs. The follow- ing algebraic rules are for review: 1. When both numbers have the same sign, the numbers are added and the sign is retained, +6 -3 +8 = a 12 Figure 3.26. Shaft A is 010 inch lower than shat B.49° Chapter Three 2. When the numbers have opposite signs, the difference is found by subtraction ‘The result carries the sign of the larger number. +40 19 =8 24 +6 Ws Consider a face-and-rim assume that the coupling hi ‘gether through a 360° rotation. Ifthe clamp and extension bar system is perfectly both indicator needles remaining at fixed ‘no change during a full rotation. ing shaft A .010 inch, shown in Fig. 3.25, The rim reading ely display a plus0,010 inch because the plunger was pushed ‘Fgure 128 Shaft is.010 inch lower than shat B. display the following readings: TABLE 22 Readings in Mis jon, The face-reading dial wll show no change the example. The rim-reading dial will50 Chapter Three gure 229 A. 1-degreeangulaiy of shaft B sade 1 the previous example “These readings are shown in Fig. 3.28. On the right side, the reading will be the combination of +10, due to the vertical offset, and the ~6 due to the horizontal ‘bottom reading will remain +20. The left side reading will be the addi- the sum of the two that the rim-reading dial indicator is used to measure the ive to another, The fixture clamp and extension bar are ‘one shaft. They then become an extension of that shaft racing out a circle that is centered on the shaft rotating center. for attached at the end of that bar can measure any deviation from ‘enter, The face indicator continued to read zero during these pure shaft B downward by 1/4 ‘midway between the ends 2.7Sinches Deflection = (2.75),00436) = .012 inch “The side face readings will remain at zero. Ifthe face indicator is zeroed at the top, the face readings will be: Measuring Misalignment 51 “The rim readings are also affected by this angular tilt. At S inches from the pivot point, the rim dial shows a deflection of 22 mil. Deflection = (5 in.)(tan 1/4°) = 022 in. ‘Atthe top ths willbe an extension of 22 mils, and tthe bottom a pushing in of ®2 aii These deflections need to be algebraically added to the previous offsets, The ‘revs rim readings were 0, +4 420, and +16. The present readings with the 11/4° angular offset becomes: Top -22 Right +4 Bottom +42 Let +16 When the rim dial is zeroed atthe top, the rim readings will become: Tp 0 Right +26 Bottom +64 Left 438 ‘A horizontal angular tilt could be added to this example to further complicate it tt will then be a realistic situation of misalignment. There is no academic purpose igre 130 The abst rim reins depend on where akong the axis ene (he mcasrements we taken52. Chapter Three Figure 331 Reverseindiatr setup on two coax sats Figure 222 Sha A is.010 inch lower han shaft B. doing this, because the important concepts have been extracted from the ex- fected by different amounts depending on where sn, This is seen in Fig. 3.30. For this reason, a ing about alignment condition, angular or paral Measuring Miselignment 53 Jel. For example, a rim reading at position B, whgscaheahaft-centerlinesiptersect, will swing zero-zero, It will portray a false impregpion that the shafts are aigned. A zero-zer0 rim dial-indicator sweep indicates alignment only in the plane being measured, imary reason for using two dial-indicator readings in two axially spaced pl the reverse-indicator setup. An example of the reverse- indicator method will now be developed progressing from aligned to misaligned conditions. Ga A on 9, ‘gure 2.34 Shaft A ie 010 inch down aad _006 inch ight fom shat B.54 Chapter Three Figure 3.31 shows a reverse-indicator setup on two coaxial shafts. The dial wanted on the clamps close to ‘and reading on target ig. 3.18(b). This minimizes bar sag since the weight of the dial indicator the extension bar. We will fassume perfect rigidity of the fixture system, such that bar sag is zero, We do not, ‘hing about the coupling. No measurements are taken rated. We could take readings on a portion of the ‘shaft, or any other auxiliary surface, even a square block attached to the shaft. The geometry of the measurement surface is not rel- evant. The only relevant measuring condition is that the measuring target be the ‘same at all four positions. lower shaft A by 10 mils as was done in the previous example. This is ‘A will register +10 mils. Dial indicator B surface is flat, no change will be seen di are rotated, and readings are taken at 90° dial ‘why two readings are needed. The answer is that only one reading will ‘parallel offset is assumed. If any angular slope is present between the shafts, (Wo dial readings become necessary. Measuring Mislignment 55 Let's disturb the shaft to have a Yé-degree downward slope as was done in the {face-and-rim example, The vertical and horizontal offsets will remain. The inter- section point of the two centerlines in the vertical plane will be between the two Fig. 3.35. The dial indicators will now display a change of i push in showing a plus 22 mils change. Dial B will extend out, change. When both dial indicators are zeroed at the top, their Figure 3.38. _A 1H englar slope of shaft B downwards added othe previous vertical and orzonal oft Figure 3.36 A pure angular slope of 1 degree in the vertical pl ly. No pall oes.56 Chapter Three Measuring Misalignment 57 <> egold be tempted to disconnect or ignore one of the indicators. "Tho validity check is a means of guarding against measurement errors. It is also possible to ise this technique to calculate a missing reading. For example, a ma- sic Ghine shaft cannot be rotated a full 360° because of some obstruction. If it can be rotated 180°, three readings are possible. The fourth reading can be calculated as Jc sum of the two side readings. The validity check for measurement errors is then lost. ‘Mr. Kenneth Brooks has extended this for situations where rotation is limited to (90°, 45° either side of top center. This is called partial rotation. The formulas are: ‘These readings are no longer symmetrical because there is an angular misalign- ‘ment in one plane. In actual practice, angular yments in two dimensions Bottom = 3.416 (Ly +R) becomes a “hunting” effort wit R,, = reading at 45° right of center re te eked pee teen? | inches to the right of dial B. This is shown in Fig. 3.36. The dial-indicator readings I ‘The center reading, of course, must be zero, For example, let's take the readings ithe got dl BT 336 The ia nera meee atk Lance If we could only swing the fixture 45° to either side, the expected readings would mils, then take another set of readings. The readings would be: O © ‘These readings show that shaft B is now low by 22 might raise it. This is obviously not correcting the angular slope. After a few frustrating moves, one “These are a fair approximation. This example suggests the possibility of greater absolute misalignment in other than the vertical or horizontal directions. Vertical | ‘and horizontal were chosen only for move convenience. Dynamic forces are not 50 ‘gravity-oriented, The true geometric offset can be calculated using the Pythagoreanfet ‘vertical and 6 mils horizontal, the true rertical. This is calculated as: fore = 11.6 mils 6 Lae ARCTAN $= 31 Graphical Calculations Dialndzator measurement af he shat do nt tel he mes Measuring Misaiignment 59 Rat the rear foot, All of the triangles are proportional, and the required moves at the feet are calculated as: “BsC AeB+e an oF R c as a ratio: 1/2 of the total indicator principle. The formulas for licator are slightly more complex because they must indicator readings. The formulas will be presented in forward from the rim readings when the angularty is corrected. Example prob- Jems are graphed in Chapter 7. ‘method, being more abstract, demands the graphical cal~ be established to keep down confusion. Ifthe align- stent manner, the procedure becomes habitual. The standing behind the motor ‘and right. Left is into the paper,‘Figure 338 View from behind the movable machine toward the fixed machine. 2. Zero the dial indicator at the top. Pius is plotted below the horizontal reference line. Minus is plotted above the line. 4, The dial closest to the motor plots the motor shaft. The dial closest to the pump plots the pump shaft. ‘Zero the left side reading. Up then becomes left for the horizontal graph. Following these conventions makes the measurement and plotting procedures routine. The alignment fixture is attached to the shafts. The dial indicators are 1 setup checked with a 360° rotation, observ chines will be moved, the grapt laid out again to contain both machines. Fea RRS for recording readings. Actual measurements are written, lated values are placed outside the circles. Good measurement technique is followed according to the previous section,tH +H Cot a Hy +4 +t ‘At this point, the validity of the readings can be checked. The motor readings are valid. 4314162447 ‘The pump readings appear to be not valid. The algebraic sum of the two side readings does not exactly equal the bottom reading, 41 —41 =-82 not -86 Minor errors are normal, especially with large dial deflections like this, The valid- Measuring Misalignment 63, ity check is primarily for detecting gross errors. The pump readings are still valid F compared to the absolute value of -86. These € bottom reading is halved and plus is plotted that the total indicator reading measures ‘The reason plus is plotted below the ‘means the plunger moved in and the lcator closest to the motor is +47. Half of this ting that dial. A vertical point comected withthe ip ofthe oe crow ‘of the pump shaft, because it was ‘Since we are interested only in the difference between ly have the numbers, we can mathematically zero the left-side readings. nd or subi these number ob sie renings ‘without changing thei "fo obtain ero left-side reading on the motor dial, we most subtract 31, Sub- ‘acting 31 from the right side leaves us with ~15. 31416 =-15 “The pump left-side reading is 41, To obtain a zero reading we must add 41(64. Chapter Three Doing this to the right side gives us zero. Plotting this will leave us with the horizontal reference line as the extended pump centerline. From the horizontal plot of Fig. 3.41, we see that the motor needs to move to the right to be coaxial with the pump centerline, The amount of horizontal movement is read by count- | ing squares—12 mils right atthe front foot and 25 mils ri rear feet awe \ a tee Pont ne ‘move correction can also be done in one step. This makes it ‘does not mea- imply teats any an be projected fis as one of ry se oe I it onto two orthogonal move directions. It recognizes only para Lt a Bota age (TEM 19 ~ THREADED BENCHMARK y ‘many possible angular ‘These graphical calc 1970s. The graphical ‘prominent alignment instructors, Even though calculations ean be comput nthe method. The graphical method provides a permar less expensive and is always available It requires only paper, pencil, “This last reason of providing more move options is a big advantage. When both ‘machines must be moved in a bolt-bound condition, the graphical method is pre- ITEM 10 COVERED BENCHMARK. thermal growth changes. These scause they are usually reversible when the sw 4 a Linn Bra ge ra {TEM 15 ~ MASONRY BENCHMARK 7 at ea ge ¥0-> th ei Let ea a ge ITEM 14 ~ WELD-ON BENCHMARK. Figure 342 Standard dancer olng balls wed a benchmark wees. .mamic, they could be considered as a low-frequency 1 10 the start/stop eycle. These dynamic movements chanics 2 “ing, The general method of detecting these “moverhents” of stationary objects is to ‘establish a refefence point -not move. The distance of two oF more points ‘on the object f to determine the methods are: 1 Mechanical Distance Measurements Optical Angular Tools fm Electronic Transducers ‘An assumption with ese methods, worth repeating, is that the reference lutely stationary. An additional assumption with only two points on that the machine is a rigid body and does not flex. Ifthe degree of to be known, more than two target points need to be measured, ce fle Mechanical Distance Measurements “The most common of the mechanical distance measurement methods is the bench- mark gages. Figure 3.42 shows some standard tooling balls. These tooling balls Measuring Misalignment 67tion of the housing. The vertical and horizontal movernents, AV and AH, can now le used to lay out AA and AB. ings along the en with no ambiguity. Fi tances A and B betwe Eléctronic Transducers be is shown in Fig. 3.46, ‘These probes come with an sransducer system mu probes have a larger range, motion, ployed in two techni Dodd bars and water-cooled Within an instrumente ‘The principle of oper target surface mat ‘generates a high-frequency signal to the an antenna and radiates a signal that in > Measuring Misalignment 69 latorfdemodulator and a length of cable. This, ixture the proximity probe rigidly tions are then attributed to target Figure 347 Operation ofthe proximity ron loco distance easuting70 Chapter Three ‘probes can be on the same bar as shown in Fig. 3.48, or on separate bars. The bars {and probes are stationary and do not rotate, The proximity probes are “zeroed” sr stands with eight proximity pr sped through the stand to maintain a ith litte thermal expansion (invar), oF perhaps fi top end of the stand also to a stable reference. tis aso important that the stand not vibrate, Its a column cantilevered up from 000 Bans wwoicar \ Prone auock machine macuine ts couruins i Figure 248, Dad bars wsed to mensre relative how Measuring Misalignment 71 tor xtre72 Chapler Three « foundation. The assumption with proximity prot atthe fixturing is abso- the only known electronic method to measure ina rotating system. It isa direct application jgnment exists when there is sliding or bending motion between foating members of coupling" (Dodd 1979) Measuring Misalignment 73 the influence of centrifugal force. A strobe light is used to 90°, or any other po Figure 3.52 shows the installa- jonary objects is a dif- than fixturing onto thethe computer can firoceed t0 cal ‘automates the alignment However, the pushing. There tues in a certa variation, because the computer is expecting val orage bins. Figure 3.53 shows around the shaft swing only 360: ‘operator does not transpose the numbers correct rotation. The computer can be a dedicated-purpose-built box with a printer, as shown in Fig. 3.54 Figure 353 Computerized alignment system, (Courtesy of Dynamies Research Corp.) Measuring Misalignment 75Figure 355. Screen personal computer. this range eilcations with pencil aight edge, and graph paper are more than sufficient accuracy. Computerized systems. do have an advantage of removing some of the me required to et the job cone? Digi ealctation cap than grphing te numbers, by about 2105 mints, Sothe about 05 minutes scones dan te-eaper. They both will then spend th tour ying to move tat 000i ae. The advange in calulation speed reutcesbe when compare tothe hl alignment ask of traveling the) rating up titres: ted moving machines The whole sigment job i tigi ote Tos Measuring Misalignment 77 ‘cantly faster, unfess the reduced confiusioysmfiheceetONMER AIRMAN A 2 TH 1 technician does not have an analog only of numbers. He/she cannot follow the motion and visualize the shaft tor. In addition, observers have @ gener ‘who is deeply concemed with the machi repairable measure- setup options are tion. The inspector can aligner can revert to computerized alignment algorithms require that one machine be stationary and the other be moveable. Tis is an undesirable restriction because + Offset: The distance that one feature from a similar feature.70 Chapter Three gure 257 Offset defines the spt orientation of ene par 10 another. Faeescky and out of roundhes eer Features of one component (itself. Mossuring Misalignment 79 ress and eccentricity. A runout measurement includes all of these effects, Fig. 356. ‘Offset isa vector quantity of one component in relation o another. Offset has an tor reading, Fig. 357, ‘the geometric center. The axis could ‘or the rotating center defined by the Figure 2.58. beet shaftFigure 350 The result of oaing and stationary sks and rating and stationary indicts offset, Fig. 3.59(6). The indicator must be refixtured to something that rotates and axis of rotation. This is the least desirable method of measuring, ‘the other imperfections. ae rote ogte, in Fi. 3.540 auch at he to determine the degree of imperfection. Chapter 4 Preparing for the Task ‘Some machines are easy to align and pose no serious difficulty. These are the ‘small machines that are easy to move, growth is not large, and boll-bound condi tions can be handled on the spot. For these, no extraordinary preparation is re~ ‘Simply gather the alignment fixture kit, some shim: g0 to the machine. If these rediate preparation is needed. kept in a vehicle or on a cart, no the jobsite on time with the position. This is a management task in logistics. instruments must have been previously purchased o universal dial-indicator system with appropriate sl handle general-purpose pumps. Second, people ‘operation that impacts raw material suppliers and deliveries to customers82 Chapter Four affected. The risks and consequences are large. There is little room in this situation for incompetence of unforeseen problems. The alignment task for this specific ‘machine must be thoroughly planned so that every potential problem can be dealt with swiflly onsite. ‘chapter is to assist in the planning of the big jobs: The all encompassing serve as a memory ‘The objective is 0 jobs. This planning is ng before any mea- ‘moved. Once the strategy is defined, personnel ‘can be assigned, instruments and tools gathered, and time planned into the sched- tule to do the proposed method of alignment. Strategy Strategy is defined as “the science or art of command as applied to the visualized at the conceptual stage and ‘The known methods of alignment wil sion of their applicability. The method to of the following methods available in his/her toolbox and approach each align- ‘ment job as a fresh problem. ir to place blame elsewhere. Fourth, it ‘of income for parts suppliers and rebui ey for them. satisfactory machine the expense. The proba ‘machines, and approaches zero with large and hot machines in mt Proparing for the Task 83 9. Use pre-existing phys ‘These are dowels, punch marks, or fixed “The machine'may have-been previously sment, patience, and schedule fr the rest of the day. ’be covered in the next chapter. taut wire or a light beam. The ‘get the bearings aligned to be co- axial prior (o setting the rotors in the bearings. placed long before the rotors arrive. More will be said about this method in Chapter 12. Optical tooling: Opt wwansit, and theodolit the alignment telescope, tilting level, jig, truments are most useful for spanning long‘84 Chapter Four 2 distances, upto several hundred fet. They are hls neff smal is: tances, being more accurate for smaller ranges: ity. These instruments ‘machine casings, and ‘The beauty of optical tooling is its general appli to align shafts. ‘over time after suitable reference points have been established. They can mea- sure flatness, straightness, perpendicularty with some accessories, and other ‘geometric features that no other instrument can handle over large distances. “The disadvantage of optical tooling is the time to set up and the skill and patience required of the operator. This subject is covered in greater depth in (Chapter 17. achieved with these at a modes “The two methods, reverse-indicator and face-and-rim, are the subjects of Chap- ters 6 and 7. These methods guarantee the minimum stresses in the couplings in the cold condition. Laser alignment is simply the reverse-indicator method with iasér-measuring i instruments have less general 1 cost, Chapter 18 covers: measuring instruments to ‘minimum stresses in the ‘coupling and bearings in the hot condition. It does not replace, but rather supplements, the other strategies. Chapter 8 describes the method. ‘These general strategies should always be kept open when planning a critical alignment. The next four sections will cover the techniques or science of de- tailed planning—the tactics. These are: . Make pre-alignment checks atthe machine. Proparing for theTask 85 “The best strategy may not be clear until the machine information has béen gathered. Gather Machine Information “This is a system survey done first by finally by walking the site. The check! at Number 8, realizing that all item: items were adopted from Murray, 1983. 1, then by examining drawings, and ‘continue with the numbering system apply. The following 40 checklist 8, Who is the supervisor or contact person fo work through for this job, for per- sonnel, permits, and job coordination? 9. Type of machinery train—two-element or mulki-element? Compressor, gear, ‘motor, turbine, pump, blower, fan, or other? Horizontal, vertical, or combina- tion? 10. Horsepower and rpm. 11. Which elements of the train remain fixed, and which are normally moved for alignment adjustment? If it appears advantageous to do so, may all el be moved for alignment? What is the best sequence for moving mul 12, What types of couplings are present? Preferably tell manufacturer, shaft diameters or approximate diameters. 14, Heights of shaft centers above nearest base or foundation point that would interfere with turning an attached chain wrench, s between shaft ends of adjacent machine elements. What. are ‘requirements (nominal space between coupling hubs)? 16, Lengths of exposed portions of shafts with couplings connected, 117, Axial distances between centers of exposed shaft sections, of adjacent ma- chine elements. 18, Any measurement access problems or obstructions? 19, ‘Types of bearings in each machine element.86 Chapter Four 20, For sleeve bearings, amount of axial float. For sleeve bearing motor, location ‘of magnetic or geometric center. 21. List any machine elements whose shafts cannot be turned manually with 22, Is the cold alignment to be made with or without thermal or running offsets? Ifoffsets are required, are they available, or must they be measured? Consider thermal, hydrostatic, hydrodynamic, torques, and gear-climbing movements 23. If thermal or running offsets must be measured, what method a tical? Essinger bars, optics, Dodd-Dymac bars, Indikon probes, Jackson 24. Is the train currently running or shut down? If running, when will it be shut 2? How long after startup/shut- 26. Are there known problems with piping fits, grouting, baseplate or soleplates, foundation or support structure, or other external factors? 27. Is the train indoors or outdoors? 28. Is it ground-mounted or elevated? ‘What provisions are available for moving the machine element(s) vertically ‘of riser blocks to allow for 432. Specify hold-down bolt sizes and lengths, number of each size, and any spe- s. Are any bolts against the edge of their clearance ‘material is type 304 stainless ‘grade 8 alloy if undercut bolts Proparing for theTask 87 34, Will standard commercial pre-cut shims be suitable, or are custom shins re- ‘quired? If the later, are dimensions oF outline samples available to permit pre-cutting a stock of shims prior to the alignment work? 38. Any/time constrains? Will alignment be on the critical path of a tumaround ‘of construction schedule’ ore than one shift be required? 36. Any other work that must be done in the same vicinity that could interfere ‘with the alignment work? If so, how will it be coordinated? Who takes prior- iy? 37. Any electric heaters or other devices that could affect machine growth or mag- netize dil indicators? If so, can they be turned off during the alignment work? 38. Any ambient noise, vibration, steam, gas, vapor emission, liquid drip, sand- blasting, guniting, welding, burning, or other extemal factors that could re quire protective action, work delay, or interruption? 39, [exposed to sunlight or other intermittent heat source, is tarp shielding practi- cal? Likewise, if work is to continue in event of rain, can tarp shelter be erected beforehand? 40, Is there adequate space near the machine to set up a couple of folding tables to hold alignment toolboxes, shim stock, etc.? ng tools out and set up. inery train currently has satisfactory alignment and is to be realigned Id it be practical aligned position? 43, Does the train have a history of probleis that could logically be attributed to misalignment? Examples could include excessive vibration, premature wear ‘couplings, premature seal failure, bearing housing cracking, failure nt growth or pipe movement be causing misalignment such that the present coupling cannot handle it satisfactorily even with the best cold alignment with best available thermal offsets? If so, should consideration‘88 Chapter Four * be'given to'a more tolerant coupling, such as an elastomeric type, or must the piping of its supports be improved? 45. What alignment tolerances are requ 46, oes the 1? If none are given, refer to Chapter 9. t have a preference for laser or dial-indicator shaft alignment? 47. How will moves be monitored horizontally? Prepare Measuring Instruments BBy this time in the checklist, the alignment strategy should be selected. This sec~ tion assumes that the “dial-indicator shaft-to-shaft” method will be used. 48. Determine the best method to use—reverse-indicator, face-and-rim, or one of the variations. The reverse-indicator method is recommended whenever pos- sible. of shaft tors with magnetic bases or clamps to monitor horizon- laser system will be used). sories that might be needed, like chain clamps for large cou sion bar to cut to length on the job site, extra joints, fixturing 54. If growth is to be measured on site, what instruments should be Infra-red thermometers, thermocouple thermometers, Essinger bars, dicators fixtured to foundation, proximity probes and stands, optical tools, lasers? 55. Paper and pencil to record data and make drawings. 56. Calculation capability—graph paper, straight edge, calculator, and computer. 57, ,Tolerance charts to determine acceptability. Prepare Tools Instruments to measure and knowledge of how much to move are half the battle— the easier half. The remaining battle is to orchestrate a precision move in three ‘dimensions of a machine that may weigh more than a house. For this task we need heavy lifting tools, along with some general tools. Preparing for the Task 99 '$8., Acquire sufficient shims of the right size. Prevcut.stainlese-stec) shims are recommended. Inspect shims for cleanliness, andapmmave burs orrolied edges. 59. Obtain several wrenches for the hold-down bolt size—open end, box end, and sockets. 60. Pack a standard toolbox with pliers, channel locks, pipe wrench, serewdriv- cers, allen wrenches, hammers, files, emery cloth, feeler gages, cleaner, oil, and rags. 61, Pack a device for rotating the shafis—strap wrench, chain wrench, or small pry bar, (62. Select the lifting, hoisting, and prying tools. These could be large pry bars, chain hoists, or special machine positic a. screws are installed, bring temporary j clamps, large C-clamps, chain puller, or commerci adjustment products. ‘64. If couplings need tobe installed or removed, bring bearing or gear pullers and ‘a propane torch. Pre-alignment Checks at the Machine ‘This brings us to the machine with a truck loaded with everything we might need. Before actually measuring or moving anything. the following checks should be performed, or convincing reasons given for not doing them, 65. If the machines are not in place, check the base for flatness with a straight edge. Grind the base or bearing pads, if necessary. 666. Clean the base and the bottoms of the machine feet. Dress these surfaces with a file to remove burrs, high spots, rust, and paint. 167. Inspect the foundation, baseplate or soleplate, and grout. Look for cracks, Weathering, or other deterioration. 668. Lock out the controls and tag them. Verify non-operation by attempting 10 start the machine. (Controls have been known to be c ed.) 31 float and coupling 869. Check, or set, the axial position, taking into account gap requirements 70. Inspect the piping for possible strain. If in doubt, measure the strain on ma- chines with dial indicators by disconnecting piping. Correct piping strain.90 Chapter Four 171. Do a rough alignment, : 72. Check for casing distortion or soft foot. Use dial indicators or feeler gages as described in Chapter 10, Correct soft foot before proceeding. shafts that are accessible, Runout of more than .003- st reason to discontinue align- aft surfaces is su ‘ment and condemn the roter. 74. On large, plain bearing machines, start the lube oil pumps, and verify circu Not al ofthe preceding checklist steps are applicable to every alignment task. ‘On most routine alignment jobs, this checklist is not done at all. These are prepa- ratory steps to plan the job when there is no room in the schedule for fumbling vance preparation will ensure that the task will proceed imely manner. attach the alignment fixture and begin “swinging” readings. ‘not valid, a the machine does not respond to movements as another opportunity to go through the checklist to examine ‘checklist was compiled very painfully after many failed its by experienced persons. Their contribution has been to pro- the things that they would have, or could have, done is chapter has been simply to compile thei lists, and in so doing, ate value. ‘Chapter 5 Rough Methods Rough methods are those that do not use precision radial measuring devices like dial indicators, and do not employ a mathematical algorithm to calculate precise ings. These rough methods use the coupling ‘measurement. Couplings are not perfect, nor Using them as references for alignment may result in not necessarily good shaft alignment. Therefore, struments for measurement, or no special- straight-edge and feeler gages as part of a experience of the mechanic, and not on high-tech instruments. le when first placing a machine onto its foun- ments. The second alignment ted. The third alignment is 2 wachine has operated for about jament after the piping is 48 hours. jon alignments easier by removing thods use right-triangle calcula- large angular misalignments. The preci ‘movements. With large angular misalignment present, the right-triangle calculation is not accurate and results in moves of the right direction82 Chapter Five but not thé éérrect amount. The alignment witl converge, ‘moves than expected. A preliminary rough alignment, espec angular deviations, will minimize effort during the later ‘The rough methods are useful to know in emergency si when no other ‘measuring instruments are available, The preferred measuring instruments could be somewhere far away, broken, or with dead batteries. In these conditions, they are useless. The rough methods can salvage the situation, and the job can proceed. ‘These rough methods will become the only available method if neither shaft ccan be rotated. When that situation occurs, the alignment method options reduce to one—this one. ‘The instruments used are depicted in Figs. 5.1 and 5.2. Figure 5.1 shows the approximate measu calipers. Some coupl in the box with instru the precision instrument ‘The rough alignment procedure is: 1. Position the machines on the foundation, 2. Add riser blocks. Flgure 5.1 Approximate measuring instruments und for rough alignment Rough Methods 93 Figure 52 Precision instrumens ted to meas coupling ap. 3. Adjust axial spacing, 4. Drill for hold-down bolts. ‘5. Do a rough coupling alignment “The machines are fist positioned on the foundation. The driven machine is imate to the other. Some consideration should be given to maintenance access and to centering the machines on any housekeeping pads. Riser blocks are added under the feet of all machines to allow for later vertical ‘manufactur the two machines. The craftsman installs them For rough aligament purposes, they should be remo. ‘machine off of the foundation. Slotted shims are pre may need to be removed later to shave some material off or to replace them with thinner ones.ing punch. ‘machines are bolted down, the rough alignment can proceed using the Nelson, four-step method BOTTOM GaP lowe 5 Thickness gauges wed to measure top and bottom gaps. Rough Methods 95 Step I — Measure the Vertical Angulatity er) gauge is inserted into the, gap at the op and botiom ofthe coupling, the gap is large, hole gauges, calipers, or inside micrometers ‘ean be used, For an accurate measurement, the gap should be measured at the outside diameter. This means that minimum insertion of the thickness gauges is ‘recommended on the open side. The moveable machine is tipped up or down and adjusted until the top and bottom gaps are equal. Calculations are typically not hes in diameter and the gap difference is .006 inch, the angularity 6mils Sinches = L2milsfinch .) If the bolt distance from front foot to back foot is 18 inches, the shim change required is: 12mils ‘inches x "E™ = 21.6 mils ~ 2 mils 62) front or rear fect, based om the direction We vertical angularity and have the two 1 offset. PARALLEL OFFSET roy | Pa Figure 54 Mestring fet wih straight ege96 chapter Five Step 2 — Measiaté:the Vertical Offset ‘A stright edges placed across the top of one coupling half and the parallel offset measured with a thickness gauge, Fig. 54, The lower unit i raised or the ‘moving an equal amount of shims at each foot. angularty adjusted in Step 1. The objective isto have vertical plane, Shimming is now complete. Adjustments can proceed to the hori- zontal plane. Reverse Indicator ‘Step 3 — Measure the Horizontal Angularity ‘The gap is measured on each side of the coupling. The difference in gaps is an indication of the angular adjustment required. The unit can be shifted sideways ‘until the gaps are equal. This adjustment is usually done simultaneously with Step icator is synonymous with indicator reverse, re Pi to a method of acquiring lateral offset measure ‘Step 4 — Measure the Horizontal Offset A straight edge is placed across the sides of the coupling halves and the Setups ‘There are three basic measuring setups to acquire knowledge about the shaft ori- entations: the coupling outside sur be tapered. 3 precision methods, all shaft align- positioning accuracies to within .005 inch, and this ‘almost all flexible couplings. The rough methods achie ‘and machines ran reliably. This can still be achieved today with some patience and skill expected of any caring craftsperson, Figure 6.1 Generic revrseindicator setup98 Chapter Six 1, Reverse indicator 2. Face-and-rim 3, Foreados method All of these employ two dial indicators, The face-and-rim method is covered in the rnext chapter. The Forcados method is covered at the end of this chapter and again ive Shafts.” Variations to these three basic setups are covered at the appropriate time. "the basic reverse-indicator setup. The key features of this tentitely permissible to take one set of dial reat then obtain the other set of sweep readings. That is, ony one dial required. Two indicators ate initially set up for convenience to make the re-arrang- icators or other sensors are closer together, the calculations ‘changes at the machine feet. That is, large foot movements ‘Therefore, itis best to mount the sensors as far ‘manageable sag. Notice in Fig. 62 thatthe indi- lamp withthe tip reading on a target block. This. ‘off ofthe extension bar and places it on the shaft Reverse indicator 99 € t gure 63 An acceptable setup for reverse indicator. tance change as the two shafts are rotated together. The indicator tip can rest on the ‘opposing shaft or on anything rigidly attached to that shaft, including the oppos- ing bracket. ‘Shaft alignment and coupling alignment are generally synonymous terms, but to point out the distinctions. Reverse indicator is always shaft ‘on the rotating shaft the coupling, such as addition to misalign- ‘can be shaft alignment if both shafts are rotated together, or cou- 1 if only one shaft is rotated. Coupling alignment can produce good results ifthe couplings have little or no runout.All eal shaft islgnment wo angular x Principles “There are four fundamental principles to the reverse-indicator method: 1, Alignment is shaft-to-shaft 2. All misalignments are angular. 3. Two points define a line. 4. Move calculations are with proportional tiangles, 1. Alignment is shaft-to-shaft. ‘eal advantage. The coupling can be installed crooked and smooth operation can ill be achieved. Shaft irregularities are also not relevant. The exposed shaft can -of-round, painted, or even a square shaft. The rotational center will Reverse indicator 101 be resolved into two angular misalignments planes. This is shown in Fig. 64 of two angular offsets. The method measures the separation of plots two points for each shaft, projects the¥ 102 Chapter Six rected in another move. Precision alignment is reduced to two moves, which can be done simultaneously. This simplifies the alignment process and makes it fast 3, Two points define a line. shaft rotational centers. These are the same asthe shaft perfect bearings. The reverse-indicator measurement show no deflector tion to be avoided. This igure 67° Move calculations using proportional wings Reverse indicator 103 ‘4. Move calculations are with proportional triangles, “The positon ofthe shafts near the coupling is nice to know, but is only an interme- dite step tothe mechanic. He/she wants to know how much to move the machine direction. This calculation is done with proportional triangles. The concept is shown 7. “The dial-indicator deflections of x and y calculate the small triangle at T. The distances to the front feet and rear feet are measured with a rule. The small triangle ‘aT is projected to the feet positions. The changes required at Foot 1 and Foot 2 are proportional to the distances A+B+C — B+C c c ‘The above discussion should make it obvious that the actual rim readings de- pend on two things: 1, ‘The misalignment present, and 2. The axial position of measurements when any angul Figure 6.8 clarifies this point for angular misalignment, sweeps 0-0, that simply means that the intersection point of the two shaft centerlines has been found. Any offset measured or reported is dependent on the position where the measurement is taken. For this reason, the coupling center is a good standard location to report offset. We cannot measure there directly, but the valve can be obtained from the graphical plot. The coupling center is a good location for ‘Figure 6.8. The rim reading i srogly dependent onthe exact axial potion of1 couplings are designed primarily to accom- ‘So it is desirable to orient the shafts with the intersection point at the coupling, ‘center. "While the offset depends strongly on the exact position of measurement, the angularty is a constant and does not need a position specifier. ‘Advantages and Limitations ‘method of shaft ligament because of its ‘not usable in all situations. It is only one of jummatize its advantages and ‘The reverse indicator is the speed and accuracy. Howevs e three major aligment methods; itis worthwhile limitations. ‘Advantages 1. The alignment is done shaft-o-shaft rather than shaft-o-coupling. 12. The coupling can remain assembled. This reduces the time for the total task ‘and removes opportunities for damage and contamination to the coupling. The measurement is taken in the same condition that the machine normally oper- ates. 3. st jlarties are not relevant, The indicator tip rides on the same point, wh Id be part of the fixture bracket, asthe two shafts rotate together, and thi ‘sweeps a circle around the rotating center. All errors are removed, ‘and the measurement is only of the alignment condition. ‘Shaft “end play” or “axial float,” with plain-bearing machines, does not affect the results. igure 6.9 Parameter for mathematically ealeusing the machine moves {fot postions 1. 2,3, or ‘not tolerate parallel misalignment very well. Reverse Indiesior 108, ‘5. The numerical difference between the opposing rim readings (i.e.,49p and hot~ tom) at any location i twice the actyal displacement between the two sha Centerines a that location where the readings were aken. Tis doubing-of the fbrolute value makes the verse indicator method more accurate than the face reading, which is a :1 proportionality between the readings and the angular ity. (6. The universal nature of the clamp and fixture system makes it more adaptable Umitations 1. Both shafts must be rotated by hand. This can be difficult on large machines or speed increasers. 2. Calculating or plotting indicator data is not ‘and-rim data to vi ity is required. Interpretation of the reverse ‘whereas a person can reason through the face- rientation. 3. Geometric accuracy will be poor ifthe indicators must be very close together, i.e, less than 3 inches. Because of the leverage effect here, the indicators will be rather insensitive to large changes at the feet. Mathematical Formulas ‘The formulas for mathematically calculating the required machine moves are de fined in this section. The formulas assume zero bar sag. The parameters are shown in Fig. 69. x= Bottom dial indicator reading on Machine M when zeroed at the top. y= Bottom dial indicator reading on Machine F when zeroed atthe top. ‘A =Distance between feet of Machine M where shim changes will be made (foot 110 2) B =Distance from inboard foot of Machine M (foot 2) tothe nearest dial indicator position, C=Distance between dial indicators. D =Distance from the inboard foot of Machine F (foot 3) to the nearest dial indic- ‘ator position 'E-= Distance Between feet of Machine F where shim changes will be made (Foot 3 tod) ‘The clamp positions are not relevant and are not even shown in Fig. 6.9. TheReverse indicator 107 108 Cheptor Six clamps can be fxtured anywhere on the shafts or Fg the coupling. | the dal indicator can read anywhere along hon afearore ASBeC sarees 2 ne ato fctr for he wiagles 3s rigid to the shaft. The positions at which the indie: significant measures. If Machine M is to be moved while Machine F remains fixed, then: (x4 MAF BHO) Vertical move at foot = 5 5 oD (+ yBHO)_y Vertical move at foot 2 = "5 7 2) : Positive values indicate that Machine M must be raised. Negative values indi- ‘cate that Machine M must be lowered. If Machine M is fixed and Machine F is to be moved, then: xt yNC+D)_* \ rr ———— 6 | ze 2 | xt yMC+D+E)_ Xx (et Wil ae os stical move at foot 4 = ~ Vertical move at foot oa A needed and negative values indicate that jeally cor Zason for one machine to be fixed and the other movable. Both mact wyerage calculation to find al interpretation of the terms < ved occasionally fo reaps for sticking to the papal ey tetiodmny be usa mater of abit, but it does fave some lear advantages. Ts the angularity. ‘graphical method: - me example): 1. Works with sufficient accuracy, It calculates moves to .001 inch or les.108 Chapter Six 2. Is almost as fast as caleulator solutions. much Tess expensive to maintain. 4, Is always available, even in remote locations, as long as a pencil and piece of paper can be found. Does not need batteries ‘5. Provides a permanent record of the sequence of moves. 6. Allows the actual shaft centerline orientation to be seen before and after each 7. Allows an infinite number of move options. “This last reason of providing more move options is @ big advantage graphical method over computer solutions. Example Problem #3 this. ‘Some conventions need to be established to keep down confusion. If each align- ment task is always done in a consistent manner, then the procedure becomes habitual. However, there will be unusual machine configurations that require modi- fying the routine proced ‘working on the eft side of a machine the usual right side because a block wall may be in the way. The com fas a stable reference to handle any and all alignment jobs. The con 1. View the problem from behind the movable machine toward the fixed ma- chine, Fig, 6.10. Left becomes into the paper and right is out of the paper. igure 6.10 View from behind the movable machine toward the Hae machine. Reverse Indiestor 100 2. "Zero the dial indicator atthe top position prior to taking readings, 3. The dial indicator closest to the movable machine plots the movable shaft. It doesn't matter where it is clamped. below the line, Minus is ploted above the ine (the horizontal ) reading is mathematically zeroed. Up then becomes left for the horizontal graph 6. Add bar sag to the bottom reading. ‘The distances A, B, and C are measured with a rule or tape measure. These foot | and dial indicator d, [tis initially assumed that the fixed machine ‘move, and there is no need to graph it If this changes during the proces becomes necessary to move the other machine, a new graph will then be con- recording readings. [Either machine can be plotted on the right or left side of the graph paper. There nt here as long as the view is from behind the movable ing left and right readings. To make Plotting Examples wing example problems are from actual field alignment jobs. They because each makes a specific point. They were not unique problems,He + eet H Figure 11 Tapesmeasred divances A Band C are transfered to graph pape Reverse indicator 111 igure 6.12. smal, high spend pump. Example Problem #1 — A small, high-speed pump misaligned from the factory “The machine configuration is shown in Fig. 6.12. This was one of three new pumps sment Was part of the installation checks 1 ron base was as shipped from {600 rpm. The small size suggests y in the mechanical system and difficulty in making precise moves i.e. overshoots and undershoots. The high speed recall a single preci at each foot. The warning indicators that alignment is needed here are: 1. There are no precision thin shims. 2. ‘There are identical spacers at each foot. 3. "The spacers were spray-painted the same color as the motor. No adjustments were made after painting, . ‘The operating man is pump stated, “The machine was precisely aligned atthe factor because of shifting during transporta- lation, it should be re-aligned on site.112 Chapter Six gure 612 nil di indicator ceding ‘The manufacturer of this low-cost pump has relieved himself of the burden of contractor with a very little bar sag—tess than ‘example problem, The measurements were taken with dial indicators, and the ini. ings are shown in Fig. 6.13. "The readings on the left are from the dial indicator closest to the motor. from the dial indicator closest to the pump. The orientation of the readings, it can be seen thatthe vertical misalignment is indicator near the motor swung +115 from top to bottom. Like- wise, the dial indicator near the pump registered a large positive excursion. This can hardly be called a precision alignment. The horizontal readings are not nearly ‘88 divergent, so the horizontal misalignment is not as bad. The readings are graphed in Fig. 6.14, For the vertical plot, one half of the botiom reading is writ ‘Actual dial-indicator readings ‘are placed outside the circle. Hal tive values are plotted below the reference line, which x's and arrow tips. ‘The graphical plot is ‘tions compared to the lr readings because we wat as badly misaligned as depicted in are correct. For the longitudinal dis ‘To plot the dial readings, a scale of ‘exaggerated in the vertical and horizontal direc, per square was used. Therefore, the Roverse Indicator 13 Figure 614 Graphical lgnment plo of» new pana deinered rom the fastthe di ‘graph. >be moved to be coaxial with it. ‘now possible to measure the movement required at the motor used to plot the tbe moved for the two shafts to be co inboard feet. Both outboard feet ings were taken withthe important. The left-side reading can be mathematically zeroed. The subtract 70, To maintain the ide must also be done to the side, “The right-side reading was +52. The adjusted reading is +52 horizontal readings for the motor dial indicator become zer0 on the raph, “The pump readings are similarly adjusted to make the Minus 5 is added to both sides. Plus 38 and - 5 equal +33. ide reading was zeroed. plottedgFor the motor shaft, one- 18 Four 6.15 Fal graphical plot of new pump fer precision signet.116 Chapter Six zontal orientation of the shafts can now be seen and the required movement mea- sured from the grid. “The two shafts intersect horizontally very close to the motor’s inboard feet, so ‘no movement is required here. At the outboard feet, the motor needs to move .008, inch to the left to be in perfect coaxial alignment with the pump. ‘These graphical plots illustrate the shaft orientations, projected onto the verti- cel and horizontal planes. The true thre mn is the combina- tion of these two projections. The point to be made here is that these plots land show at a glance the severity of the misalignment. If the assembler at the factory saw these, he/she could have added another 1/4-inch spacer block at each foot and been closer in alignment! ‘The motor was adjusted with two moves, Shims were added and a horizontal adjustment made, Another set of swing readings were taken, and another graphical pplot done. A second adjustment was made both vertically and horizontally. The final dial-indicator readings and graphical plot are shown in Fig. 6.15. The vertical than the pump shaft. This factory. In all fairness, many good manufacturers do a recognized that this good alignment can change due iping strain, and thermal growth. For these reasons, and before placing the machine in service. Unfortunately, one or both of these alignments may be omitted. parchasers of this, and delete claims about precision alignment in ‘consequences are that owners or installation contractors may omi Te fo ae of Figure 6.16 High-speed blower contigation. Figure 637 (a example is evidence that not all mi though the manufacturer claimed, in our real world, is that precision aligiment new machines should be:checked for aligh- ‘ment. Let physical evidence be the final judge =148 Chapter Six Example Problem #2 — A high-speed blower that was boltbound “The machine configuration is shown in Fig. 6.16. This was a blower at « waste Water treatment facility coupled to a 100-hp motor. This machine was eight year tid. and the motor bearings had worn out. The motor was removed and trans returned, the owner req ‘The motor was elect alignment fixture was attached to the shafts. This fixt ‘used in the previous example and spanne 8 inches. This span generated significan re-alignment. to be .003 inch Fil be compensated for in this problem. Bar sag will be covered formally and ‘Chapter 10. This example problem will simply introduce how to correct for bar sag. are shown in Fig. 6.17a. Are these valid read fays be done for any raw readings. This is the de indica be correct Town inthe lower part of Fi. he edge of the clearance ition of boltbound existed. The motor could not be to handle bolt-bound c the two boll gure 610 Grapical lt of inital eins comet or ar 88.120, Chapter Six Figure 619. Final alignment check. Reverse indlestor 121 else 622 = 10625) tack 2 2 ‘This was more than enough. A. ignment check was made after making this ial indicator on the blower registered an exc bottom. When these readings are corrected ent conclusions. The readings mi loted before any meaningful conc! Example Problem #3 — Moving both machines. ‘This problem involves a height-bound condition where the motor needs o be low- visually averaged. This plastic base was chosen for its noncorrosive characteristics because the pump handled a brine solution. The flexibility in the base complicated the alignment. MoTOR 7 reene7 Boren te {ene Figure 6.20, Mote/punp combination for Example Problem #3.the motor was also heightbound vertically der ofthis example probl gure 6.22 Ina readings pote fr the bie pump.126 Chapter Six second set of swing read rnin Fig. 6.23. “The side-to-side readings are almost identical for the motor, and are similarly ‘equal for the brine pump. This, indicates that the horizon even though a small correction could be made. From this ‘nly on the vertical correction. This second set of reading ‘This plot now shows the entire machine Jength laid out was done because consideration must now be given to moving both Isat the outboard feet and inch shims removed were the motor, realizes at this point that lunch the options. Take the graphi- 3k. Perhaps find a cold drink or ing. I know some aligners who such situations. fo complete. A litte thought and reasoning at this point can save hours of unnecessary effort, The reasoning goes something like this: ‘We have initially declared one machine to be fixed and the other movable. This is normal procedure and a good way to approach any alignment job. Dec! more easily mobile machine t be the movable one, Howev ion when movement becomes limited by a hard physi raise the pump’ ‘no” in this case because the angularity hip is such that both s pointing down toward each other. This is shown in Fig. 6.25. Either machine Figure 624. Second set of reatngs plated. The ete machine length i raped and only te veil plo shown.motor were considered fixed, the pump would 24, itcan be seen that the pump would need ‘and 179 mils. The pump has to the plastic base. It canno tothe outboard pump feet. This dashed ined. represent a new elevation. higher than this dashed ‘require shimming at more than two feet Reverse indicator 127 igure 6:26 aration f the revere indiatr method with «wo dial indicators ona ‘ommoa extension ba ‘The moral imple problem is to consider moving both machines when movement is iitaneously moving both machines provides the greatest ‘opportunities, The graphical plot provides not only visualization of the possibili- ties, but also allows measuring exactly how much to move atthe feet or any other adjustment location. Variations “The method of measuring alignment on long drive shafts, described in Chapter 11, ste fabricated jigs rather than commercial shaft clamps. Where convenient, use existing coupling hardware or threaded holes to jon bar to, The extension bar does not need to be round, gr even ‘only to be rigid with the shaft. Structural angles work well be- is where rotation is limited to something less than 360°. If at jon can be achieved, the fourth position can be calculated. How-128 Chapter Six ever, when this is done, the validity check for errors is lost. f less than 180° of ‘available, the remaining readings can sated with the continuity ‘obtain alignment data with no the measurements around the shaft of shaft rotation at all. The fixture clamp will need the coupling. The measuring and graph indicator method. The results, s expected, smoothness, straightness, ‘way to rotate the shafts. ‘Chapter t Face and Rim Figure 74 The hate ia indicator setup or fe andr messesFace and Alm 131 alignment are almost always taken with me- ty probes could be used, ed wide popularity because the u yet wraps around the shaft. No l Jem has ever been made, presumably because the face reading would require an ferometer distance measurement. Mechanical dial choice for the face-and-rim method. The basic setup is shown in surement, The coupling can -and-rim setups are shown in |, oF Fixtured, onto the rotating shi 3 indicator reading on a rotating surface ture is never clamped to a stationary shaft unl “The ideal practice is to rotate both shafts togethe always read on the same spot. This way, the condition of the coupling evant, and in fact, itis possible to accurately align the shafts even ifthe coup! 10 independent measurements. The rim reading reading measures angularity. Because the toceasily separate the two Theory ‘One point and an angle are sufficient to fully define a line. Thi ‘behind the face-and-rim method because the point and angleat the dial indicators read on. The other shaft centerline is JJamp and extension bar, reverse-indicator rates the points and angles located. ith the left shaft and rotate wi defined by the fix ‘method. Figure 7. ‘The clamp and exter extension bar will rotate a “truc’ assuming zero bar sag. The “true 3s eylind ‘he bearings supporting the lft sha. The plane ofthe clamp defines Point 1, and the plane of rotation of the rim indicator defines Point 2. The two planes have se pvaxial separation, s0 this is sufficient to locate a Tine—the centerline of the reads some variation during a 360° rotation. One- tance defines ‘concentric with the a tan indirect measure of the angle «. The difference be- “when on 180° opposing sides, measures b, in Fig. 7.4 ing defines the adjacent leg D. The angle s can then be calculated as shown in Fig. 7-4 "The face-and-rim theory is b offset. The angular the alignment condition of ly Figs. 6.5 and 6.6. There .-indicator method, or a face reading, to locate two shafts in space. Tha absolute value of the face readings depends on the diameter of swing. A Face and Rim 133 larger diameter will cr face readings for the same angulariy. Conse. ith large-diameter couplings, the face-ati-rim method sreater geometric accuracy forangutarty: For ikneaten, isREpre- ferred method of aligning large machines. The face-and-tim method is also better cally have plain bearings, and these can caus . and these can cause problems of end float, of axial float. End float is the freedom of a shaft to slide axially between its thrust bearings. ‘There are three ways to handle end float: Push the rotor against its thrust bearing for each reading. 2. Use two face indicators, and take the difference. This method is described as a variation at the end ofthis chapter—the three-indicator method. 3, Use the reverse-indicator method, which is not bothered by end float. Calculations D DIAMETER OF SWING A= arctan Ze he TOTAL FACE READING ngulrity fom the Fae reading.oR ‘jovece mevaney FF eS els 7 aura 75 Perec fr calling Foo erent wing te eovansin mai ot necessary, The parameters for the calculation are shown in Fi 75 and are defined here. Distance from measurement plane to the rear feet As B= _Distnce from the measurement plane 1 the fron feet D_ = Diameter ofthe dial-indicator swing on the face b= Bottom rim reading when zeroed at the top ve reading when zeroed at the top = Required shimming at the front feet R= Required shimming at the rear feet With the two dia-indiator readings nd the three tape measurements the required ‘with these two formulas: moves are calcul Fabra a . 7.2) With these two equations, the vertical angularity and vertical ofS corrected Fi st ove_One move is defined asa singe shim change at each oot Positive Face and Rim 135 values for For R indicate thatthe motor must be raised. Negative values for For R © jndicate that the motor must be lowered. ‘The interpretation of these two formulas is as follows: be D js the offset in the plane of measurement. It is the true paral angularity. This value must be subtracted to move the it the plane of measurement. for angularty and offset are done taneously. This way we need onl lation can be done for the horizontal zeroed at the top. For the horizs 4 side, The right-side reading will then become in the formulas, With this convention, positive Values for F and R will indicate that the motor must move left. Negative values for F and R will indicate that the motor must move right te Sa Flour 7 Face anim example problem$5 BARSAG -005" —pgueg 7.7 Ina ia-ntcatoreaines ai Comes fo bar Sg Example Problem ‘This example problem tim readings. The machine pump driven by an 1800-rpm elect imensions are shown in Fig. 7. the Fim reading does. The correction for bar sais to add the amount of sag 10 the bottom reading. The correction for this example is: 486452491 ing is negative on the bottom. This means that the indicator plunger ‘outward when going from top to bottom, so the bottom gap is wider. Thi that the angularity is such that the rear of the motor is higher than the fer by half this amount, or 45.5 mils lower. The true orientation is as ig. 78. Fig. 78 that the motor lowered, more at the rear feet For some craftsmen, t faras the calculation will go— of the orientation readings. An aligner could now ‘proceed to remove some shims based on an estimate and then swing a new set of a " I : ld sos geadings:"The alignment process can move along rather quickly this way if we dispense with any caleulations Face and Rim 137 ‘Wien the shim changing is complete, the aligner would bump the motor hori- face and rim are about the same. ly by an experienced aligner with- ‘The calculated moves based on Equations 7.1 and 7.2 are: Vertically Bb Fab Ba (a5) 2 Fh 2 68-45.5=-113 dover a nab A Ma (as) 1 Sh 114455 =-160 Gowen Horizontally Mathematically zero the left-side readings to obtain the differ- ‘ence side-to-side. 460-6020 Left Rim 427-602-338. Right Rim (@,) -10+10=0 Left Rim “1S+10=-5 Right Face (b)) QO Figure 7 Interpretation of raw dial inticator readings95) (-33 F=(-5)[ 22 |-[ 3? 2-144 16.5 = +3 Leh ‘ (53) ( z } “” 16 _(-33 R=(-5) 20 -[ |= -23 416.5 =-6 Right) O35 ( 2 ) Cc) ‘Afeer three adjustments, the final readings are shown in Fig. 7.9. These are ments were to be made, the required moves for the serious student 10 calculate i condition is acceptable. ng drive shafts with two face ‘When the coupling gap is too small to insert a standard AGD-style (American Gage Division) indicator, then other setups can be used. These are: 1. Use feeler gages to measure the gap. BAR SAG .003 2 ° 7 Figure 79. Fina face anim eines Face and Aim 139 Figure 711, The Frcados method with wo face readings 2. Measure on the back side of the coupling, Fig. 7.2(a). This will introduce even. ‘ereater bar sag, Also, the sign ofthe indicator reading will need to be reversed to use Equations 7.1 and 7.2. Use a universal icator, Fig. 7.26). ‘The three-indicator method is used to manage end float, The indicator setup is shown in Fig. 7.10, Two face indicators are installed to read at 180° opposite loca- “The shafts are then rotated 180°, such that and indicator C is on top. The B and C dial ym face reading is:140 Chapter Seven By using two dial indicators on the face, any end float can be,neglected. The rotors can slide any amount and in any direction, and this measurement method ‘vill compensate for that axial movement. The difference in dial-indicatot from top to bottom is the important face reading for angularity. The addi indicator is our zero check, or reference. Since two icator readi ‘taken (one will go positive while the other goes negative), the average of the (wo readings is the true bottom reading for angularity "The Foreados method with two face indicators is used on long drive shafts with Jurement setup is shown in Fig. 7.11. The couplings re- main assembled and, in fact, must remain intact to support the drive shaft. This method is useful for cooling towers and where the drive shaft penetrates through a hole in a wall. The wall or other obstruction prevents spanning the full distance, ‘and it will be necessary to use this method because no other Wi ‘The face-face Forcados method assur there is no parallel off is only angular misalignment at each two couplings. The need for rim readings. ings. More on this meth Comparison of Methods “The major alignment methods have been thoroughly covered, and this is @ good place to compare them, Some additional methods have not been introduced yet, Fe., optical methods and running alignment, but they will be compared in the table also, Table 7.2 lists the known ‘ments needed, advantages, and disadvantages. "No two alignment tasks are exactly alike, and then there are the unusual jobs that require some creative setups. For these reasons the aligner should have more than one option available. “The reverse indicator isthe preferred method for shafi-to-shaft ali it can be used, The instruments used to acquire the rim readings tasers, or electronic gages—are not relevant to the results. They cs ‘equivalent final results, It is the method itself that is superior. It is generally more fccurate because there is a larger ratio of measurement span to foot span. “The reverse-indicator method also requires that some calculations be done. It {does not allow the mechanic to use “trial-and-error” movements. This can be an Stdvantage or a disadvantage, depending on the mectianic’sattude, The face-and- © rim method, on the other hand, allows visualizing the angularity and offset from the raw readings. ‘Atiees smoot runing condion Poste safety consrat "The only method avalble when a wall” Sighly poorer grote ‘Coupling tly need tobe daasembed Dinara Pli-beanng machines fer ober gen tks Cant eed bot shat se ot ole by and secwacy tan Read im Tera movement oe etry cing operation “Time coniming reed pals, perpendicular, Natess, Opera skil and maetik Check resus with inustry sandads als sling Backes we sod (Cheek esas with indy stondards Axil loa err ca our on Benet geomeuic scarey than RI. on large-diameter couplings The oaly metod sslabie to check coher echaical component ke bearings, gasps, ec. Pression alignene "The most waiver agnor ‘Minima insane Frsison agent Simple eleiatons Grapicalcleulations End Not rfactor Fart Coupling remains assembled prevents saningshafo-tat Tnsrments Newded inden Fire clamps or brackets ‘il indicator oer Faure clamps or brackets “To fixture clamps Neither safc be ruied— Sgh ege when fist plicing machine Fel gages "Too dl adeno Dall Vibration meter ‘Ava reves spanning the brackets Appicaiy couplings ful aisines Forfa wig ajsinents “Gong dive shal with two ‘Generally applicable every Ruming Alignment ‘TABLE 7.2 Comparison of Alignment Methods Faceand Ri Foresdoe RoughChapter 8 Moving Machines able. Some are easier to move than others. The start of ly considers one machine fixed and the other movable. If th no heavy piping attached. Perates af temperature extremes, consider first moving, the machine that operates closer to ambient temperature ‘The only absolute rule to retain is that ever adjustability depends mostly on the tools thing can be accomplished adjustable. The degree of With the proper tools, any- aEvery skilled professional has unique tools of the trade. Ithas been said that a man ‘Murray has listed the contr idle almost every conceivable situat fc alignment toolbox and borrows some concepts from Malcolm G. rament task can be divided into five categories: Gaining access: “This means transporting toolboxes to the machine, making it safe to work on, and removing guards. the method, and personal pre will be emphasized here, with the ‘substituted where appropriate. Moving Machines 145 Vehicle Tnclinometet, 4-point For taking readings _ level Dolly or cart ‘Torpedo level, inch Lock and tag Basic wrenches and serewdrivers Channel lock pliers Regular pliers ‘Allen wrenches For coupling Setscrews, aaa ei ee ‘wrench146 Chapter Eight Moving Machines 147 1e may have been made when the done onboard and internally to is. no choice here except possibly inch or metric 7 ibility todo stor A good, cost-effective combination to use with dial- ind easuring instruments—as a check of graphi- cal plotting and to avoid confusion. es, 20 and 8 tos per pi capacity, respectively‘Some of these tools are illustrated “Moving Machines 149, To dress base and bottoms of feet. Figure @.1(e) Positioner operating principle ‘Tool Description Purpose Installation instructions Use a checklist prior to energizing machine. Grease gun Lubricate bearings, and coupling if required. (Use ‘clamped or bolted to the base. izontal movement. When the al ped of unbolted and placed i lamps, or pipe clamps, are another idles the machine base and hooks over a stationary edge. The clamp- ing serew is used to push against the machine foot and draw it toward the other side.150 Chapter Eight, Figure 8.2. (a) Permanent jacksrew installation, and (D) temporary and portable jackscrew. Procedure Figure 8.3 illustrates the general alignment procedure when first positioning two machines, TOUGH ALG VERTICAL 8 WR, T ‘SETUP pat TsTow Siero EASE WORTTORTAL PRECISE MEASURENENTS ANVERTICAL OFFSETS ve 002 tnt TORTENTAL WOVE Frere] OPERATE WAGHTNE & VERIFY LOM VIBRATION Figure 83 Pow chart ofthe general shaft to-shafsignment procedure Jing is typically done only once em after removal for repair. This ictated by the coupling to be used. n firs installing machines, other se of readings The ligament fixture remain slached during these aus ments.ment is the ability to 10. AXTAL SPACING — 4 4 @ AXIAL SPACING Figure, 4. Axil spacing define, C r cup Moving Machines 153 Fe one move alignment is possible but unreasonable to expect on all machines S'_pecause of fonlinear behavior for both meas wd align i assim

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