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ALIGNMENT HANDOUT
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Factors Influencing Alignment procedure
1- Eccentricity (runout)
Check
· This might be done by a dial gauge
4- SAG
· For spacer couplings, a sag (deflection) check should be done on the indicator
bracket to be used for the alignment.
· The DBSE in these couplings may be long, and when alignment brackets are
clamped to one hub and extended to the other hub, there is a tendency for them to
sag.
· This sag can alter the dial gage readings, leading to misinterpretation and errors.
· For bracket lengths larger than 25–30 cm, it is essential to provide additional
stiffness to minimize sag.
· It is therefore necessary to perform a sag check of the bracket.
· A sag check is essential only for aligning horizontal machines, because the sag is
caused by gravity due to the weight of the bracket.
Alignment techniques
· There are many methods to align a machine. The appropriate method is selected
based on;
Ø the type of machine,
Ø rotational speed,
Ø the machine’s importance & production,
Ø the maintenance policy and
Ø alignment tolerances.
· Machines “I”
{Which are not fragile (breakable) in their construction}.
Ø rotating at less than 1500 rpm,
Ø lower horsepower range,
Use merely a straight edge to align machines.
Considering all aspects, it is acceptable to align them to the range of 0.3–0.8 mm.
Machines “II”
{Majority of machines}
Fragile (breakable) in their construction (mechanical seals and expansion bellows)
Machines operating at;
Ø speeds of 3000 rpm and higher,
Ø in the medium power range of 20 kW–1 MW
should be aligned within 0.1 mm.
· This requirement necessitates the use of comparators like dial gages, and
methods with minimum residual errors.
The dial gage functions based on the rack-and-pinion principle. The conventions
that are followed are shown in Figure 6.9.
Thus, the convention maintains left and right when standing behind the driver,
facing the driver.
Left and right readings on the dial gage are recorded accordingly.
Types of misalignment
Misalignment in machines is due to;
· angularity and
· offset,
· but in almost all cases the misalignment of machines is a combination of both.
i- Angularity
· is the difference between the values on the comparator (dial gage) for a half
revolution”180o” (because for one complete revolution we return to the original
position).
· For a given angular misalignment, angularity depends on the diameter described
by the dial gage.
· It can be seen that when d1 increases to d2, p1 increases with the same ratio to
p2. This value must be fixed when a certain tolerance is given (Figure 6.13).
Angle of misalignment:
Where p1, p2 = dial gage reading when rotated by 180°; d1, d2 = diameters
described by the dial gage.
· The dial gage readings would indicate the diameter, and hence should be reduced
by half to obtain the true offset reading.
· The ‘F’ in Figure 6.19 indicates that these are facial readings,
meant for angularity corrections.
· Two sets of calculations are required. One set for the vertical plane and the other
for the horizontal plane.
*Angularity correction
· Let us say the angularity readings for the top and bottom readings were 0 and - 2
mils, respectively.
· If the dial gage pointer is touching the rear face of the motor coupling hub see
(figure 6.9).
· The negative sign indicates that the coupling has a narrower gap at the bottom
than at the top.
The dial measures at (scribes) a circle of 5 in.
The angle
Because the angle is very small, the tan inverse function can be neglected:
Hence, P1=.002 in.
(The formula would reverse if the pointer is touching the front face of the coupling
hub, which is normally the case when there is a long spacer between the couplings.)
= 0.0004 radian
=0.4 milli-radians = 0.0004´ (180/p) = (0.023o)
· This angle “θ” is also the angle of inclination of the motor axis w.r.t. the pump axis.
· Line AB is the existing axis inclination of the motor (Figure 6.21).
· It must be lifted by amount x at the FF (front foot) location and by y at the RF (rear
foot) location.
Where;
S = arc length;
r = radius;
θ = included angle in milli-radians.
Final- Vertical
The final results should include corrections for both the offset
and the angular corrections.
At point A{Front Foot FF}:
Offset results – remove shims of 2.5 mils
Angularity results – add shims of 3.2 mils
Thus, insert shims of 0.7 mils under the front foot of the motor.
*Angular calculations:
Left reading: + 4 mils
Right reading: - 6 mils
+ 4 means that the left point of the motor hub is away to the
pump hub by “4”.
- 6 means that the right point of the motor hub is close from the
pump hub by “6”.
{To imagine this, just draw the dial gage and its direction}
As the dial pointer touches the rear face of the motor coupling
hub, the shaft axis resembles what is shown in Figure 6.22.
In this case:
mils = 0.01 inch.
Thus:
Hence:
x = 2 ´ 8 = 16 mils – move to the left;
y = 2 ´18 = 36 mils – move to the left.
Figure 6.22
Final- Horizontal
· Once the vertical shims are adjusted, the bolts should be tightened and a quick
test of the vertical plane reading should be made to confirm the accuracy.
· If the accuracy is satisfactory, the bolts can be loosened and the horizontal
alignment should be done with jack bolts (if provided).
The limitations of this method are:
· Calculations are necessary, which may be difficult to do in the
field.
· It is beneficial to be able to visualize the shaft orientation from
the dial gage readings but this requires practice.
· Inexperienced technicians can find this confusing.
· Errors in calculations may occur if there is bracket sag and/or
error in the dial gage readings.
· If the shaft of one or both the machines has substantial axial
floats, the angular readings can be erroneous.
Laser alignment
Alignment with comparators such as dial gages characterized
by;
· a fair degree of precision,
· demand skill,
· demand training and
· Require experience.
Consequently, these methods are;
· tend to provide errors and
· can take a considerable amount of time.
ROTALIGN PRO
(Laser shaft alignment system)
COMMENTS
Some said…
god good i found your blog...nice content you have here..keep it up please..
October 1, 2009 at 12:16 PM
Anonymous said…
Thank you
fred
March 8, 2010 at 7:53 PM
Wisam said…
I am an Electrical Engineer from Syria and I am currently in Korea. I have just used your
blog (this page) to explain so a Korean package manufacturer what does a "Clock Gauge"
means. They usually call it a dial gauge.
A wonderful article on the Alignment and is very useful for the Engineers to get help
from it.
October 20, 2011 at 2:59 PM
Anonymous said…
how nice job. its very useful information each n every technical person must read.
srinivasa rao
October 18, 2012 at 9:23 PM
Like your way of seeing things! Still you may do some things to expand on it. Thanks for
sharing with us!
HIMT
August 14, 2015 at 8:19 AM
Great work! I love the way you have written this so beautifully! keep writing!
double column machine
March 23, 2017 at 1:37 PM
__________________
Ansal Institute
April 26, 2017 at 11:37 AM
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Amr Zoair
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I am a mechanical Engineer,
working for Orascom
Construction Industries
Algeria, as Heavy
Equipment Workshop
Manager.
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