Shaft Alignment

Basic knowledge and Method osf shaft alignment

1. Shaft Alignment Prepared By Muhammad Nadeem (EMT)

2. Contents • Introduction/Definition • What are the symptoms of misalignment •Pre Alignment Checks • Types of Alignment • Alignment Method •Effects of Misalignment.

3. Introduction/Definition Shaft alignment is the positioning of the rotational centers of two or more shafts such that they are co-linear when the machines are under normal operating conditions .  Proper shaft alignment is not dictated by the total indicator reading (TIR) of the coupling hubs or the shafts, but rather by the proper centers of rotation of the shaft supporting members (the machine bearings).

4. What are the symptoms of misalignment Premature bearing, seal, shaft, or coupling failures. Excessive radial and axial vibration. High casing temperatures at or near the bearings. Excessive amount of oil leakage at the bearing seals. Loose foundation bolts or broken coupling bolts. The shafts are breaking (or cracking) at or close to the inboard bearings or coupling hubs.

5. Pre Alignment Checks Soft Foot This condition occurs most frequently well known as table leg condition. Soft foot causes frame distortion. Two methods are commonly used for soft foot correction Tighten all hold down bolts then loosen one bolt at a time and note the deflection Soft Foot checks Dial Gage Feeler Gage

6. Pre Alignment Checks Bracket sag The Inclination towards downwards in alignment Bracket due to gravitational force is called Bracket Sag . Corrected Indicator Readings True Indicator Readings = Measured Readings – Sag Readings 0.05 mm 0.05 mm

7. Pre Alignment Checks Run out Shaft & Coupling

8. Types of A lignments Before we start learning about the procedure for alignment it is very important that we first know the types of misalignments. Generally there are two main types of misalignments P arallel (also known as offset) A ngular (also known as gap) In parallel or Offset misalignment, the two shafts to be aligned have centerlines that are parallel to each other but are in offset condition.

9. Angular Misalignment angular misalignment the axis of the two shafts are located at an angle to each other. angular misalignment can be further subcategorized as either horizontal or vertical misalignment. Angular horizontal misalignment occurs when the motor shaft is at an angle with the pump shaft, but both shafts still operate in the same horizontal plane. Angular vertical misalignment occurs when the motor shaft is at an angle with the pump shaft, but both shafts still operate in the same vertical plane

10. Alignment Methods & Resolution Laser

11. The feeler gauge and straight edge method This is the easiest method of alignment, but it is also the least accurate, and is not recommended for high RPM machinery. It's only recommended for machines fitted with flexible couplings capable of tolerating up to 1.5° angular run-out and 0.25mm parallel run-out .

12. Alignment Methods Using Indicator Rim & Face Shaft Alignment Reverse Shaft Alignment Applications Rim & Face Shaft Alignment Trains where one shaft can’t be rotated during the alignment process. Machines with coupling hubs that are axially close to each other. Machines that have large diameter couplings. Small general purpose machines Reverse Shaft Alignment Long span machines Machines that require precision alignment.

13. Correct & Collect Readings & Calculation in Rim & Face. Since any alignment readings taken by this method will include not only misalignment but also bracket sag, sag must be removed from the reading to yield only misalignment . Calculation shims for Angular Alignment using the formula given below :“ C”Shims Required = Angular Displacement X C / A B”Shims Required = Angular Displacement X B / A Calculation shims for Parallel Alignment using the formula given belo w Shims Required = Parallel Displacement/2

14. Reverse Shaft Alignment Graphic Method

15. Graphical Solution

16. By Formula for Shim calculation in R everse dial

17. By Formula for Shim calculation in Reverse dial

18. By Formula for Shim calculation in Reverse dial

19. Laser Alignment Laser shaft alignment is the most efficient way of aligning machine shafts. Put simply, it saves time and money: increased machine availability, prolonged service life and maintenance intervals, lower power consumption ! Easy to Use Even for Beginners Quick and Easy Set-Up of Fixtures Measure with a Smaller Shaft Rotation Consistent Results and Easily Recordable Data Error free and accurate measurement: No human uncertainties, no bracket sag influence and no reading errors Straightforward alignment procedure: System can be used by any operator Quick on-screen laser beam adjustment Universal precision brackets designed for quick and rigid set-up Automatic computation of horizontal and vertical coupling and foot values Clear graphical representation of the machines with the corresponding foot correction value and direction “Live move” shows updated values and the direction of the correction. Reports generated directly from instrument, in conformity with ISO 9001 documentation requirements Powerful Software

20. Laser Alignment Tool Parts

21. Effects of Misalignment Excessive Vibration  – Misalignment is one of the leading causes of equipment vibration. In spite of self-aligning bearings and flexible couplings, Noise  – Like vibration, noise can be detected simply by noticing a change in the equipment sounds during operation. All running equipment produces a certain normal amount of noise. Only if an operator is familiar with normal equipment noise will they be able to detect abnormal sounds. Lost Production  – Misalignment can directly affect the lifetime of equipment. With a shortened service life, equipment will require unplanned maintenance, thereby reducing the time available for production. Poor Quality of Products  – Product quality can suffer directly from equipment misalignment. Misalignment can cause both the manufacturing process to produce defects and directly damage product. Higher than Normal Repair Orders  – Misalignment-induced failures will increase the amount of unplanned maintenance, causing more repair orders to be generated. Increased Inventory of Spare Parts  - As the amount of maintenance increases due to misalignment-induced failures, more spare parts will need to be ordered. This results in increased spending and a larger spare parts inventory. Reduced Profits  – As machines fail early and unexpectedly, more money must be spent for maintenance and spare parts. Coupled with lower production, misalignments can rapidly reduce profitability.

22. THANKS Thank you so much for your patience & kind attention !!!