Section Five

Misalignment

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Misalignment

• Objectives
– ID Misalignment w/spectral & waveform.
– Use Phase to distinguish Misalignment
from Unbalance.
– Describe single-channel analysis
techniques.

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Misalignment

– Characteristics of Misalignment
• High Axial levels
• High radials at 1x, 2x, or higher harmonics
• 180° phase across coupling
• Repeatable time waveform
• Excessive bearing temperatures
• Coupling failures
• Oil leakage at seals
• Shaft breakage at or close to couplings

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Misalignment

• Shaft Center Line Misalignment

– Two types of shaft center line misalignment
are discussed.
• Angular
• offset or parallel
– Most misalignment problems are a
combination of both.

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Angular Misalignment

Angular misalignment occurs when the center lines of two shafts

meet at an angle. The shafts can be angled in the vertical or
horizontal planes. The spectrum typically has a dominant peak at
1xTS in the axial direction. Radial readings in the spectrum will
show peaks at 1xTS and 2xTS if offset misalignment is also
present. The highest vibration usually occurs in the direction of
the angularity, which means that if the angularity occurs in the
horizontal direction, the highest vibration should also appear in the
horizontal direction.
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Angular Misalignment

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Angular Misalignment
The waveform characteristically is sinusoidal with one or two clear
cycles per revolution. The waveform amplitude in g’s is low and
does not show much impacting.

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Angular Misalignment
The typical phase relationships for angular misalignment are:
B A
D C
The horizontal phase
relationship from A to B is
180° ± 30°.
0° 180°

B A
The vertical phase D C
relationship from A to B
is 180° ± 30°.
0° 180°

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Angular Misalignment
0° 180 °
B A
The axial phase D C
relationship from B to
C is 180° ± 30°.

Note: Do not forget to

take the transducer 0° 0°
orientation into B A
consideration on axial D C

readings. Confusion
here could lead to
making the wrong call.

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Offset Misalignment

With offset misalignment, the shafts are parallel but displaced

from each other. The shafts can be offset in the vertical or
horizontal planes. The spectrum shows a predominant 2xTS peak
in the radial direction. The highest vibration usually occurs in the
direction of the offset. Since the coupling forces the two offset
shafts to meet, it introduces some angular misalignment. This can
cause a 1xTS peak in the radial and axial direction that exceeds
the 2xTS peak.

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Offset Misalignment

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Offset Misalignment
The waveform is characteristically sinusoidal with one or two clear
cycles per revolution. The waveform amplitude in g’s is low and
does not show much impacting.

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Offset Misalignment
The typical phase relationships for Offset Misalignment are:
B A
The horizontal phase D C
relationship from B to C is
equal to 180° ± 30°.
0° 180°

0° 180°

The vertical phase B A

D C
relationship from B to C is
equal to 180° ± 30°.

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 5-9
Shaft Component Misalignment

– A partial list of possibly misaligned

components are listed below :
• Pulleys
• Gears
• Couplings
• Bearings
– This section will cover only couplings and
bearings. Pulleys and gears are discussed
in detail later in this course.

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Coupling Misalignment

– Coupling misalignment : The spectrum

can have multiples of 1x to 6xTS and
harmonics in both the axial and radial
directions depending on the type of
coupling used.
– The appearance of the waveform will be
dependent on the fault type and the
coupling type. It can vary from very
periodic and sinusoidal to very random with
impacting.

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Coupling Misalignment

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Coupling Misalignment
Phase Readings will typically be a combination of offset and
angular characteristics.

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Bearing Misalignment

Bearing
Center Line
Induced Bearing
Angle

Shaft
Center Line

In bearing misalignment the spectrum normally has the highest

peak at 1xTS, 2xTS, or the number of rollers xTS in the axial
direction.

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 5-11
Bearing Misalignment
The waveform often shows a truncated or flattened pattern
indicating a rub. It may also appear periodic and sinusoidal with
low amplitude.
The typical phase relationships of bearing misalignment are:
The axial phase relationship
from A to C is equal to
180°± 20°. A
The axial phase relationship D B
from B to D is equal to 180°
± 20°.
C

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Bent Shaft

• Vibration can vary depending on where the

shaft is bent. If the shaft is bent near the
center, the spectrum has a dominant peak at
1xTS in the radial and axial direction. It can,
however, appear at 2xTS if the shaft is bent
near the coupling.
• The waveform will resemble a mixture of
misalignment and imbalance. Keep in mind
that the shaft is actually out of balance.

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Bent Shaft

0° 0°
B A
D C

The axial phase relationship

from A to B is equal to 180°
± 30°. 0° 180°
B A
D C

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Bent Shaft
B A
The horizontal-to-vertical phase D C
or
relationship on A and B is equal
to 90° or 270° ± 30°.
90° or 270°
Horizontal to Vertical
A1

The axial end phase relationship from D1 B1

A1 to C1 and B1 to D1 is equal to
180° ± 30°. C1
Axial End Phase
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Bent Shaft

• Remember that the phase data will be

180° out across the bend, not across
the coupling.

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Case History #1 Quench Fan
•100-HP, variable -speed motor.
•Direct-driven, overhung fan.
•High axial readings on Fan Outboard.

FOH, FOV,FOA

Direct Driven Overhung Fan

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Case History #1 Quench Fan
Notice that the highest amplitude is in the axial direction
at fan running speed

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Case History #1 Quench Fan
If the axial measurement point was not taken it would have
been difficult to diagnose this problem as angular misalignment.

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Case History #1 Quench Fan
Notice the waveform is repetive and lacks complexity.

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Case History #2 Main Cake Mixer
•75-HP, four pole motor.
•Drives a double reduction gearbox.
•Mtr. Spd. Vibration present on all points.
•1xTS primarily in horizontal direction.

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Case History #2 Main Cake Mixer

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Case History #2 Main Cake Mixer

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Case History #2 Main Cake Mixer

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Case History #2 Main Cake Mixer
Angular misalignment because of the axial vibration load.
But it’s angular in the horizontal direction.

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Case History #3 Process Fan
• 250-HP motor.
• High horizontal on fan bearing.
• 0.025 to 0.030” runout on FOH point.
• 1xTS in the horizontal direction.
F1H, F1V,F1A

Direct Driven Overhung Fan

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Case History #3 Process Fan
Phase data was a key to solving the problem. 180° shift top
to bottom and side to side on the FOH bearing.

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Case History #3 Process Fan
The waveform displays a repeatable, sinusoidal pattern.

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