Alignment presentation

Basic of Aligment

1. MACHINERY ALIGNMENT API 686 Presented by M. Asif SO-PM III

2. Table of Contents (a) What is Alignment (b) What is Misalignment (c) Types of Misalignment (d) Method of Alignment (e) Symptoms of Misalignment (f) Pre Alignment Checks (g) Tools Required For Alignment (h) Alignment Tolerances

3. What is Machinery /Shaft Alignment ? Its the process of positioning of two or more machines that are coupled, so that centre lines of rotating shafts form a single line when the machines are under normal operating conditions.

4. Aligning Your Machinery Mean… performance and protection of industrial equipment. Increase operating time . Increase production Cost saving

5. What is Misalignment & Types Misalignment is the deviation of relative shaft from collinear axis of rotation when equipment is running at normal operating conditions. Shaft misalignment occurs when the center lines of coupled shafts do not match up. There are two Types of misalignment. O ffset/Radial Misalignment Angular /Axial Misalignment

6. Radial Misalignment Radial misalignment can also sometimes be referred to as parallel misalignment because the two shafts, or axes, are parallel but do not line up. Radial Misalignment can be further classified as Radial Vertical Misalignment Radial Horizontal Misalignment

7. Axial Misalignment Axial/ Angular misalignment involves an angle just as the name implies. It occurs when one of the shaft axes is at an angle in relation to the other. Axial Misalignment can also be classified as Axial Vertical Misalignment Axial Horizontal Misalignment Combination

8. Misaligned Your Machinery Mean.. Is a risk to your business. Lead to unplanned production stops. Consume more power. Can affect the quality of the product you are manufacturing. Financial loss.

9. Types of Misalignment Parallel Displacement or Radial Displacement Face Displacement or Angular Displacement Combination

10. Method of Alignment Rough Alignment 1 = Straight Edge ,steel rule & Wire Method Precision Alignment 2 = Rim & Face Method 3 = Reverse Method/Graphical Method 4 = Laser Method

11. Method of Alignment

12. Symptoms of Misalignment Premature bearing, seal, shaft and coupling failure High vibration High Casing / Bearings / Oil Temperatures Excessive oil leakage from bearing seals Coupling is hot Foundation bolts get loosen Coupling bolts /Shims broken or loosen Shafts are breaking (or cracking) at or close to the inboard bearings or coupling hubs Similar machine has less vibration

13. Effects of Misalignment Misalignment can cause the following problems on the running machine. Vibration in the machine and associated / linked equipment’s. Excessive wear and temperature rise in the bearings. It causes coupling failure. Abnormal noise arises Over loading of prime movers Decreases the efficiency of the machine

14. Causes of Misalignment Thermal Expansion Stress. Soft foot. Bearing Failure. Vibration. Poor workmanship.

15. Mechanical Causes of Vibration Unbalanced rotating components. Damaged impellers A bent or warped shaft. Misalignment Pipe strain. Either by design or as a result of thermal growth. Thermal growth of various components, especially shafts. Rubbing parts. Worn or loose bearings. Loose hold down bolts. Loose parts. Damaged parts.

16. Why Precise Alignment is needed? Now trend in industry is towards higher speeds, higher horsepower and less sparing . These factors increases the need of precise alignment and balancing to minimize vibration and premature wears of couplings, bearings and shaft seals. Stresses from misalignment are directly proportional to the speed of unit.

17. Alignment States Cold Alignment Alignment which is carried out when the machine is at cold state. Hot Alignment Alignment which is carried out when the machine is at hot state.

18. Pre-Alignment requirements? Foundation Grout Base plate Piping Coupling Installation Soft Foot Shims Sag Feeler gauge

19. Foundation Adequate size and good condition Thumb Role Concrete weight should be equal to three times machine weight for rotating machines Concrete weight should be five times for reciprocating machines

20. Grout Should be in good condition Tapping with a small hammer can detect hollow spots

21. Base Plate Should be rigid Machine mounting pads should be level flat and clean .

22. Piping Well fitted and supported. Stress Free. Sufficiently flexible, no more than 0.08mm vertical and horizontal movement occurs at coupling

23. Coupling The coupling should be installed with a light interference fit with shaft. Vary from .002”to .005”per inch of the shaft diameter.

24. Soft Foot Machine feet do not rest flatly on the base of machine . Soft foot is cause d by de f ormed machine base plates or deformed machine feet . T his method is commonly used for soft foot check & correction. Place the Dial at foot of machine. Q Tighten all hold down bolts then loosen one bolt at a time and note the deflection Maximum soft foot allowable limit is 0.05mm

25. SOFT FOOT

26. Shims The shims used should be large enough to adequately support each foot. Don’t use Dirty shims-Clean them Many shims replace with fewer thick shims Use Pre-cut stainless steel shims Don’t reuse painted, or badly bent shims Best choice for shim material is stainless steel Maximum shim limit is12mm Try to use max 5 or less shims under each foot. Its not always possible but try to minimize

27. SAG The Inclination towards downwards in alignment Bracket due to gravitational force is called Bracket Sag . Sag does not normally effect horizontal alignment . But in vertical measurement it depends on the spacer length Q For less then 6” length of the spacer sag is negligible. Q For spans greater then 6” sag should checked & Note down.

28. SAG CHECK Dial Travel

29. Thermal Growth For liquids 93 C ° and below set motor shaft at same height as pump shaft. For liquids above 93 C °, set pump shaft lower or motor shaft higher as per OEM Recommendation. For foot mounted pumps or turbines Q Thermal growth (mils) = 6x [ To-Ta] x L/100 Q L = distance from base of shaft to foot Q To =operating temperature C ° Q Ta =ambient temperature C ° Note: Apply these formulas only if alignment data is not given by OEM

30. Overhung Pump Radial Flange Bolts Some times these bolts are use for achieving alignment better procedure is to bring all bolts to light torque and then continue to full tightness while observing with dial indicator such that no shaft lateral movement occurs. Example =AMU-P-101A/B Note : Normally experienced person do not recommend this method

31. Tools req’d for Machinery alignment Dial Indicator (two dials) Two brackets (for reverse indicator method) Straight Edge/ Steel Rule , Meter tape Venire Caliper Micro meter Inspection Mirror Crowbar Tool Box Shims

32. Alignment with Straight edge/Feeler Gauge. Allowed only on flexible coupling, as precise alignment can not be achieved. Radial misalignment is checked / corrected with the help of straight edge or knife edge. Axial misalignment is checked / corrected with the help of feeler gauge & ID Mic. This method is used only for aligning the shafts of non critical machines. Alignment Methods (Cont .)

33. Pulleys /Sprockets Alignment With Steel Rule/Straight Edge V Belt pulleys or sprockets can be aligned with straight edge bars/Steel Rule or strings.

34. In this method, as the name suggests, graphical techniques are used for aligning the rotating members. One set of readings is taken from the loose machine to the fixed machine, and the second set of readings is taken from the fixed machine to the loose machine. It is therefore sometimes referred as reverse method. These readings are then plotted on the graph using suitable scale. How much the rotating members are misaligned, can then be calculated from the graph. Graphical or Reverse method

35. Graphical Method Movable Machine X Z Fixed Machine D2 Y Only one of above indicator orientations will allow you to graph the shim changes in such a manner that a positive indicator reading always means to plot up and a negative indicator reading always means to plot down, D1

36. Advantages : More accurate than Rim & Face Method. Readings are not affected by axial float. Disadvantages: Should not be used on close coupled shafts. Difficult to take readings on long shafts Advantages & Disadvantages Reverse Method

37. Laser Method The most modern & accurate method for aligning the shafts. Laser alignment is the process of determining misalignment by a laser beam. Where laser is mounted on one shafts and a receiver or reflector is mounted on the other. Both shafts are turned at the same time. The deviation in the laser beam is measured as the shaft is turned and readings show on Display Unit.

38. Laser Alignment kit Parts 1 Display unit 2 Cell or batteries 3 measuring units with spirit levels 4 mechanical shaft fixtures 5 locking chains with tightening pin 6 Measuring tape (imperial and metric) 7 Machinery shim starter kit 8 USB communication cable 9 Quick Start Guide 10 Printed User Instructions 11 Hard carrying case 12 Informational Cd

39. For using dial indicators, it is necessary to prepare a suitable Fixture, which can hold two or three dial indicators One dial indicators (R), with the axis in the radial direction, will measure the radial misalignment of the shafts. And one dial indicator (A) with the axis in the axial direction, will measure the axial misalignment of the shafts . Rim & Face Method

40. Dial Indicator works with the index of mm scale. Before rotating the shaft and collecting the misalignment data, ensure that all the dial indicators are set to zero. Also make sure that traveling margin is available in these indicators. When recording the data, the plus sign shall be given when the rod of the dial indicator goes back into its seat or move inward . Minus sign shall be given when the rod comes out . When the dial indicator main pointer rotates by 360 , the dial indicator small pointer will show 1mm displacement of the rod Dial Indicator

41. ACCURACY VERIFICATION Each time the dial indicator is rotated to the top location it should display a reading of zero. If it does not then something has moved during the rotation: indicator, bracket, clamping mechanism, machine. Correct the problem and start over. Another test, which can be performed as the data is collected, is to verify that the sum of the top and the bottom readings should equal the sum of the left and right readings.

42. Place the dial on the rim & Face of the coupling hub and secure it with the help of suitable Fixture. Measure the data during a rotation of 360 The algebraic sum of the values read on the horizontal plane (90 & 270 ) will be equal to the values read on the vertical plane (0 and 180 ). Rim & Face Method

43. To perform the Rim & Face Method, By Formula you must: Mount the dial indicators fixtures. Measure the A, B, & C dimensions. Obtain as-found readings. Determine the vertical foot positions. Make vertical corrections. Make horizontal corrections. R e-measure and record final alignment values .

44. F =0.3/2 + 0.8x465/-150 0.15+2.48=2.63mm R =0.3/2+ 0.8x1255/-150 0.15+6.693=6.84mm

45. Advantages : Good for large dia coupling hubs where the shafts are close together. To be used where one of the shafts can not rotate during alignment. Easy to use. Disadvantages: Difficult to take face readings, if there is axial float in the shaft Requires removal of coupling spool. More complex alignment calculation Too much manual work Indicator Sag Advantages & Disadvantages of Rim & Face Method

46. Comparison

47. Important Tips Clean the Machine Base, Removes Rust, burrs etc. Perform pre-alignment checks on machine Use correct bolt tightening procedure. Use jack bolts Try to put the stem of dial gauge perpendicular to the surface of coupling hub Check indicator sag Check Run out of(Bent shaft, Out of round couplings) Check the coupling gap

48. Important Tips After decoupling the machine, take alignment reading, if time permits. It serves as a reference reading, as some time it becomes difficult to get the desired readings . Before alignment, always ensure that there is no “soft footing” in the machine. If it exists, remove it prior to align . Use Jacking Bolts For move the Motor Never use Hammer If the machine has more than four feet, then it is better to carry out the alignment of the machine by reverse / graphical method. Always carry out the alignment job in the early day time. NOTE Down the Time while taking the final Readings

49. Alignment Tolerances Parallel Angular RPM mm Inch RPM mm Inch 0 - 1000 0.13 0.0051" 0 - 1000 0.10 0.0039" 1000-2000 0.10 0.0039" 1000-2000 0.08 0.0031" 2000-3000 0.07 0.0027" 2000-3000 0.07 0.0027" 3000-4000 0.05 0.0019" 3000-4000 0.06 0.0023" 4000-Above 0.03 0.0011" 4000-Above 0.05 0.0019" NOTE: These tolerance should be used were manufacturer recommended tolerances are not available.

50. FINISH