Professional Documents
Culture Documents
2- Types of Couplings
4- Preparation on Alignment
5-How to Do Alignment
Hassan
1-What is shaft alignment
A- Shimming
B- Moving a machine component.
Proper alignment
1 -Rigid Couplings :
It is a metal to metal contact (%100 collinear)
2 -Flexible Couplings
Motor Equipment
Coupling
Pump Grouting
Equipment Driver
2 –Flexible Couplings
Equipment Driver
*Spacer with shims
*Spacer with shims
Equipment Driver
*Gear
Equipment Driver
*Grid
Equipment Driver
Torque
converter Stationary
Guide wheel
Turbine Liquid
Secondary
Shaft
Cooling water
Pump Primary
Impeller Shaft
Packing
Pumps Turbine
MOTION
MOTION
HYDRAULIC HYDRAULIC
ENERGY ENERGY
Higher speed Lower speed Normal speed
14 Confirm suction and discharge nozzles are installed as per design and
alignment is correct and stress free.
Confirm pipe strain checked and corrected.
16 Confirm bearings and seals are clean and free from damage
17 Confirm coupling hubs are clean damage free and match marked.
Organization
Sign
Date
Parallel misalignment
Vertical
Driver
OR Equipment
Horizontal
Angular Misalignment
Equipment Driver
Vertical
OR
Horizontal
Correcting of Misalignment
I- Vertical Plane
A- Parallel Misalignment
Equipment
Shims
I- Vertical Plane
B- Angular Misalignment
Equipment
Shims
II- HORIZONTAL Plane
A- Parallel Misalignment
26
II- HORIZONTAL Plane
A- Parallel Misalignment
1 3
2 4 27
II- HORIZONTAL Plane
B- Angular Misalignment
1 3
2 4 28
Dial indicators Types and Functions
1- Balanced-Type
40 4
-50 05
0
• 2 - Continuous Type
Small needle
10
190 20
180
30
170
160 40
50
150
140 60
130 70
120 80
110 90
100
Preparation on Alignment
The following preparatory steps should be taken before
attempting to align a machine train:
EQUIPMENT
PLANT LINE
* Soft foot One driver leg is not
settled on the base
Maximum 0.002 “
Correcting for Soft-foot
• Three of the four chair tips will always rest on the floor.
Consequences
Placing a piece of machinery in service with
uncorrected soft-foot may result in the following:
• The nuts securing the feet to the base may loosen, resulting
in either machine looseness and/or misalignment. Either of
these conditions can cause vibration.
• If the nuts do not loosen, metal fatigue may occur at the
source of Soft-foot. Cracks can develop in the support
base/frame and, in extreme cases, the soft-foot may actually
break off.
• Initial Soft-foot Correction the following steps should be
taken to check for and correct soft-foot.
• Before setting the machine in place, remove all dirt, rust,
and burrs from the bottom of the machine's feet, the shims to
be used for leveling, and the base at the areas where the
machine's feet will rest.
EQUIPMENT
SHAFT
Growth factors (Expansion factor) (mil/in./F)
for common materials are as follows:
Aluminum 0.0126
Bronze 0.0100
Cast iron, gray 0.0059
Stainless steel 0.0074
Mild steel, ductile iron 0.0063
• For vertical growth, L is usually taken as the vertical
height from the bottom of the foot where shims
touch the machine to the shaft centerline.
• In the case where the machine is mounted on a base
that has significant temperature variations along its
length, L is the vertical distance from the concrete or
other constant temperature base line to the shaft
centerline.
* Thermal growth for hot liquid pumps
1- Apply the alignment procedure for the pump at ambient Temp.
2- Heat up the pump by opening the start up bypass for ½ hrs.
3- Put the dial indicator on the shaft and adjust to zero reading
4- close the bypass
5- Take the dial indicator reading after 24 hrs.
6- This reading is the shaft thermal growth thermal growth
7- Add the center line thermal growth reading under the driver legs
Equipment Driver
* Thermal growth for Compressors
1- Apply the alignment procedure for the compressor at ambient Temp.
2- Go to catalogue and read the center line thermal growth amount.
3- Add the center line thermal growth reading under the driver legs
4- If the equipment manual gives the hale equipment thermal growth
The center line thermal growth = The hale equipment thermal growth /2
After minutes
of Starting
Driver
Equipment
Equipment
Cooling
water
48
*Magnetic centre.
Electrical motors have no thrust bearings
as they have instead a magnetic center
Magnet
Magnetic centre 49
Measurement of bar sag.
The attachment that will be used
SAG
Steel block
Dial indicator
Piece of Pipe
SAG
Sag factor
SAG
How To Do Alignment
Gauge Pointer
does not move around the rim
Equipment Driver
The same
Misalignment
Driver
Equipment
VERTICAL READINGS
Parallel actual x
misalignment
HORIZONTAL READINGS
Parallel actual
misalignment
If : x
- Both shafts rotate
Or - One shaft rotates
2x
1-Reversal Alignment
Equipment Driver
M
F M
Fixed Movable
12 Ock 12 Ock
0 64
0 0
36 0
62
6 Ock 6 Ock
PARALELL READINGS
Fixed Movable
12 Ock
12 Ock
20 0 40
0
6 Ock 6 Ock
1-Reversal
Alignment
Calculation
Method
F M
D1 = 0 64
D2 =
D3 = 20 0 0 40
Sag = (0)
36 0
/2 /2
/2 /2
VERTICALLY
D2
INBOARD = { MV - FV } D 1 + FV
{ } D3
OUTBOARD = MV - FV + FV
D1 10 FH MH +20
HORIZONTALLY
{ } D2 FV 18 MV +32
INBOARD = MH - FH + FH
D1
{ } D3
OUTBOARD = MH - FH + FH
D1 Mils
VERTICALLY
X D2
INBOARD = X + FV
MV- FV
=
D1
INBOARD = { MV - FV } D
D1
2
+ FV X
}
= MV- FV }
D2
D1
MV- FV
X
Inboard
FV MV FV
F M
D1
D2
66
VERTICALLY
Y D3
OUTBOARD = Y + FV
MV- FV
=
D1
OUTBOARD = {
D3
MV - FV } D 1 + FV Y
}
= MV- FV }
D3
D1
MV- FV
Y
Out board
FV MV FV
F M
D
1
D3 67
D1 = 4 in F M
D2 = 8 in 0 64
D3 = 16 in
Sag = ( 0) 20 0 0 40
F = 0
M = 0 36 0
/2 /2
/2 /2
VERTICALLY
8
INBOARD = { 32 -18 } 4 + 18 = + 46
16
OUTBOARD = { 32 - 18 } 4 + 18 = + 74 MH +20
10 FH
HORIZONTALLY
INBOARD = { 20 -10 } 84 + 10 = + 30
FV 18 MV +32
Outboard
Inboard
MV Remove shims
(+) FV F M
D1 Add shims
D2
D3
71
Vertically
FV = 18 mils
MV = 32 mils
Inboard Outboard
32 mils
18 mils
Remove shims
F M Add shims
4 in
8 in
16 in
Horizontally
D3
D2
D1
Outboard
Inboard
F M
MH
FH
73
5/3/2006
EXAMPLE
FH = 10 mils
MH = 20mils
Inboard Outboard
20 mils
10 mils
F M
4 in
8 in
16 in
3-Reversal Alignment Software
Sag
Sag Factor
D1 D2 D3 Factor(F) (M)
2 4 8 0 0
0 40
ADD shims
20 F 0 0 M 40 REMOVE shims
Move towards 9
Move towards 3
30 0
15 -1 20 1
15 20
10 15 20 20
Transducer Reflector
F M
Equipment
Driver
Bracket Bracket
Chain Shaft
SIDE VIEW
HRIZONTAL 0 VERTICAL
ANGLE 90 PRISM
POSITION
ADJUSTTMENT ADJUSTTMENT
Bracket
Shaft Chain
Transducer
GREEN LED:
INDICATES BEAM
ADJUSTEMENT
RED LED:
LASER ON
WARNING
HOUSING MARK
= CENTER OF
BRACKET POSTS
LOCKING
KNOB
SCRATCH-RESISTANCE
LENS
POEWR
DATA CABLE
REFLECTOR
1- PRESS M and remove transducer cap.
-The laser beam now is on.
-Leave the reflector cap on for now.
-Beam strikes the cap, it should be visible.
- Hold a sheet of paper to locate the beam
HORIZONTAL
ADJUSTMENT
VERTICAL
ADJUSTMENT
OFF Beam misses detector
Red Blinks quickly
Green Is OFF
OFF
d- Thermal growth
HORIZONTAL MACHINE ALIGNMENT
1-Transducer to reflector
3-Coupling diameter
4-RPM
4 RPM
5 6
DIM
1-Transducer to reflector
120 mm
3- Coupling diameter D
BEAM
DEFLECTOR
DIM
• Case Studies
For Alignment Failure
RADIAL BEARING THRUST BEARING
ball Bearings
roller Bearings
HANGED BEAM
IMPELLER
Thrust Ball
Bearings
MECHANICAL SEAL
BEARING HOUSING
Thrust Load
DRIVE END
NON-DRIVE END
IN-BETWEEN TWO
BEARINGS IMPELLER
Mechanical seal and bearings arrangement
Equipment
THRUST PAD BEARING
CASING
SHAFT
THRUST
COLLAR
Titan 130 Thrust Bearing
Radial Tilt-Pad Bearing
RADIAL TILTING PAD
BEARING
CASING
SHAFT
Radial
Load
Oil Wedge Oil
squeeze
between
shaft and
bearing
Due to
pad
Oil
forming a
Surface
solid
Tension,
oil wedge
And high
speed,
The Oil
adhere to
the shaft
Forming
an
Oil Ring
Oil Wedge
Shaft
RADIAL TILTING PAD
BEARING
TILTING PAD
SHAFT
PIN
OIL
CASING
CAVITATION
OCCURS
CENTRIFUGAL
PUMPS
AND
Pump M. Seal
Vertical
Inline
Centrifugal
Pumps
Driver
Coupling
Gearbox
Pump
What is cavitations
phenomenon
P
Kg/Cm2
80
Liquid
Add
Temp
60
Lower Pressure
40
Vapor
Vapor
20
14.7 Psi
212
A
Vapor Pressure Graph through
pump the impeller
P
Kg/Cm2
Cavitations
start
Vapor
pressure
limit
Impeller length
FLUID VAPOR
BUBBLES
cavities
CARBON STEEL
BRONZ
BRASS
ZINC
What is cavitations effect
1- centrifugal pumps
• Impeller
deterioration
• Decrease discharge
pressure
• Decrease pump flow
rate
• Increase vibration
level
• Bearings & M/S
2- reciprocating pumps
• Suction valve
• deteriorations
Spring Rupture
• Decrease discharge
• pressure
Decrease pump flow
• rate
Cylinder Head
• Damage
Piston Damage
NPSH
1- net positive suction head Required
You can get from pump manual
PS v Z
Ps
The suction
Gauge pressure
Or
Pvs
Liquid level in
The suction vessel
Z
1 PVS
General Equation
Z
V
2
V { Psasva – Vp } 2.31
NPSHA = Z + 2g
+ - hL
Sp.gr
2
If The Suction pressure is known
PS
v
2
NPSHA = V { Psa – Vp } 2.31
+ ( ft )
2g Sp.gr
Boiled
water
Positive
Reading
PS Z
Z < hL
PS
PVS
Negative
Pressure
PS
Z < 6m
ATMS
Practically
PS
- Z = 6 mt of water
ATMS
76 Cm 10,033 mt
MERCURY OF WATER
ATMS ATMS
Pump Eff.= 100%
VACUUM PS
v
PS
10,033 mt v
OF WATER PS
ATMS
v PS
PS
6 mt v
WAT
ER PS
Centrifugal
Pumps losses
Friction loss
Eddy loss
Leak loss
H ft Theoretical Heat loss
Curve
ACTUAL
CURVE
Q g.p.m.
100 200 300 400 500
VAPOR PRESSURE
1
1 P
T P T
FIG-1 FIG-2
P Absolute P gauge + 1
(bar)
Vapor Pressure P Gauge + 1
( bar ) absolute
Temp C 100 95 90 80 70 15
P Gauge 0 - 0.1 - 0.3 - 0.5 - 0.7 - 0.98
Liquid vapor
Liquid
T = CONSTANT
Examples
Crude oil level is 8 feet above center line
of a pump , Vessel pressure is Atmospheric
Vp is 4 psia
Sp gr. is 0.8
Friction loss : 12 ft of liquid ( Neglect velocity head (
Atmospheric pressure is 14.7 psia
Solution
Solution
NPSHA = Z + +{ (Psv+ Pa) – Vp } 2.31 - hL
Sp.gr
{ (0 +14.7) – 14 } 2.31
= 8 + - 2
0.85
= 8 + 2 - 2
= + 8 ( ft )
Compare with NPSHR
negative
If the liquid level Z= - 12 ft
Friction loss is 1 ft of liquid
Atmospheric pressure is 14.7 Psia. at 150 F
water sp gr. is 0 . 982 ( Neglect velocity head (
Vp = 3.7 psia FIND NPSHA
Solution
NPSHA
( Pa – Vp ) 2.31
= Z +
. gr
hL ( ft )
Sp
Solution
{ (Ps + Pa) – Vp } 2.31 ( ft )
NPSHA =
Sp.gr
{ (( 0 +14.7) - 5 )) – 4 } 2.31 ( ft )
=+
0.8
= + 16 . 46 ( ft )
If the liquid is butane and level is Z = - 8 ft
System pressure is 60 psia.
Temperature is 90 F
Vp = 44 psia at 90 F, butane sp.gr is 0.58 ( Neglect velocity head (
Friction loss : 12 ft of liquid, FIND NPSHA
Solution
NPSHA
Z ( Psva – Vp ) 2.31 hL
= + ( ft )
Sp
. gr
( 60 – 44 ) 2.31 hL
= -8 + ( ft )
.
0.58
= + 43.7 ft
Solution
{ Psa – Vp } 2.31
NPSHA = ( ft )
Sp.gr
= { (1 + 14.7 ) – 13 } 2.31 ( ft )
0.85
= + 7.33 ( ft )