ALIGNMENT

Machinery Systems Design and Installation

FOR ENGINEERS

Presented By
Hesham M. Khalil, PhD, CEng

Rotating Equipment Section Head

Egyptian Natural Gas Company, Gasco

Lecturer,
Mechanical Engineering Department
University Of Alexandria
Misalignment ?

Misalignment is the condition when the centerlines of two coaxial shafts don’t form a straight line
Definition
Alignment ?

The process of reducing the misalignment of two adjacent shafts so that the
Definition center line for each shaft is as near collinear as practical.
Parallel (Offset) Misalignment?

The distance between two adjacent and parallel shaft centerlines. This offset is
Definition normally described in a unit (millimeters or mils) at the flex element location.
Parallel (Offset) Misalignment?

Definition
Angular Misalignment ?

The angle between the shaft centerline of two adjacent shafts. This angle is
Definition normally reported in slope of millimeter of change per meter of linear distance
(mils per in.) (1 mil = 0.001 in.).

Millimeters of change per meter of linear

distance
Combination Misalignment ?

When the centerlines of two adjacent shafts are neither parallel nor intersect.
Definition This misalignment is normally described in both angular and offset terms.
Consequences of Misalignment

► When shafts are misaligned, forces are generated.

These forces resulted in:

• Vibration.

• Noise.

• Bearing, coupling or shaft damage.

• In extreme cases, the bending stresses applied to the shaft will

cause the shaft or coupling to fracture and break.
Consequences of Misalignment
Consequences of Misalignment
Consequences of Misalignment
Why we need alignment ?

► Reduce wear on components

► Reduce vibrations

► Decrease power loss “power saving”

► Decrease loads on the bearings and

fittings flexing of shafts

Alignment Applications

Coupling
This is typically encountered in
pumps, compressors, and gas
turbines.
Alignment Can
Be Done To
Motor Sheave/Fan Pulley
This is typically encountered in
air coolers, and blowers.
Couplings
Couplings

Coupling Types

Rigid Coupling Flexible Coupling

Why do we need flexible coupling

• Transmits Power or Torque Mechanical Coupling

• Power - HP or kW
• Torque - lb-in or N-m Elastomeric Coupling

• Duties from < 0.1 kW to > 100 MW

• Transmits rotation from 0 rev/min to 80,000 rev/min Metal Membrane

• More flexible with misalignment

Couplings

Flexible Coupling Types

Mechanical Coupling Elastomeric Coupling Metal Membrane

Jaw Coupling Metal Coupling

Gear Coupling
(Compression and Shear Types)
Couplings
Mechanical Gear Coupling

• Requires Lubrication
• Transmits very high torques through splines
• Accommodates misalignment by clearance
between splines
Couplings
Mechanical Gear Coupling
Couplings
Elastomeric Jaw Coupling

• Low torque Capacity So, it has a

limited power capacity.
• Accommodate misalignment by
elastomers deformation/sliding.
• No lubrication needed.
• Lower cost.
Couplings
Elastomeric Jaw Coupling
Couplings
Membrane Metal Coupling

• Reduce Maintenance.
• Easy to fit.
• Reliable (Infinite Life).
• No lubrication.
• Low loads on bearings.
• Low induced vibration.
• Safe to operate
• Wide operating envelope
Couplings
Membrane Metal Coupling
Couplings
Installation
Couplings
Installation
Sources of Misalignment
Piping Strain
Deviation of Operating Conditions than
Ambient Conditions

80 % of Chronic Failures
Improper Alignment
Coupling to Shaft Run Out

Motor Soft
Foot
Improper Foundation Design
Alignment Tools

Dial Indicator Clamps Shims Feeler Guage

Straight Edge Taper Guage

Alignment Tools

Vernier Caliper Laser Alignment Kit Torque Wrenches

Open/Closed Wrenches Mirror Level Bar

Alignment Tools
Dial Guage/Indicator
Alignment Tools
Dial Guage/Indicator
Alignment Tools
Dial Guage/Indicator

Positive and Negative Readings

Alignment Tools
Dial Guage/Indicator
Positive and Negative Readings
Alignment Tools
Dial Guage/Indicator

Various Styles, Sizes and Ranges

Metric Dial Indicator

Alignment Tools
Dial Guage/Indicator

Various Styles, Sizes and Ranges

What is the reading ?

Alignment Tools
Dial Guage/Indicator

Various Styles, Sizes and Ranges

What is the reading ?

Alignment Tools
Dial Guage/Indicator

Various Styles, Sizes and Ranges

What is the reading ?

Imperial Dial Indicator

Alignment Tools
Dial Guage/Indicator

Various Styles, Sizes and Ranges

Alignment Tools
Dial Guage/Indicator

Application for Dial Gauge

Alignment Tools
Brackets, Clamps and Bars

Used to fix the dial gauge on the coupling face or rim in addition to rotate both coupling (if applicable).
Alignment Tools
Brackets, Clamps and Bars

Used to fix the dial gauge on the coupling face or rim in addition to rotate both coupling (if applicable).
Alignment Tools
Brackets, Clamps and Bars

Used to fix the dial gauge on the coupling face or rim in addition to rotate both coupling (if applicable).
Alignment Tools
Brackets, Clamps and Bars

Dial Indicator Clamp

Alignment Tools
Brackets, Clamps and Bars

Dial Indicator Clamp

Alignment Tools
Shims

• They are placed under the mounting feet of the

drive unit to align it in the vertical plane.
• It is recommended not to increase number of
shims more than 5
Alignment Tools
Shims

Pre-Cut Shims

• It is recommended to use pre-cut, motor

base, stainless steel shims. Although their
initial cost is greater than brass shim
stock.
• Standard thicknesses from 0.001" to
0.125" and to guaranteed thickness
tolerances.
Alignment Tools
Shims
Alignment Tools
Shims
Alignment Tools
Feeler Guage
Feeler gauge is a compact assembly of high-quality,
heat-treated steel leaves of various thicknesses.
Alignment Tools
Feeler Guage

Alignment Soft Foot Check

Alignment Tools
Straight Edge
Alignment Tools
Taper Guage
Its principal advantage for coupling alignment is that it gives a direct reading and does not require trial-and-error
"feeling" to determine a measurement.
Alignment Tools
Taper Guage
Its principal advantage for coupling alignment is that it gives a direct reading and does not require trial-and-error
"feeling" to determine a measurement.
Alignment Tools
Laser Alignment Kit
Alignment Tools
Vernier Caliper
Alignment Tools
Vernier Caliper
Alignment Tools
Torque Wrench

A torque wrench is a tool used to precisely apply a specific torque on nut or bolt.
Alignment Tools
Wrenches/Spanners

Used for coupling bolts tightening and jacking screw movement to adjust the horizontal misalignment.
Alignment Tools
Lever Bar

Used for lifting the motor to install shims under its mounting legs.
Alignment Tools
Lever Bar
Alignment Tools
Mirror
Pre-Alignment Checks
Coupling to Shaft Run Out

Run out is the amount a coupling is “out of true” with the shaft.

There are two possible reasons of run out

• Bent Shaft

• Coupling Eccentricity (Offset – Angular)

Pre-Alignment Check
Coupling to Shaft Run Out

Bent Shaft
Pre-Alignment Check
Coupling to Shaft Run Out

Coupling Eccentricity
Caused by coupling offset
Pre-Alignment Check
Coupling to Shaft Run Out

Coupling Eccentricity
Caused by coupling angularity
Pre-Alignment Check
Coupling to Shaft Run Out
Pre-Alignment Check
Coupling to Shaft Run Out Coupling check for run out due to bent shaft

• Fix the bracket on the skid.

• Fix the dial indicator on the shaft almost

vertically.

• Rotate the shaft 360 degree and check the max

reading.

• If the reading was more than 2 mils (0.002”) the

shaft shall be replaced.
Pre-Alignment Check
Coupling to Shaft Run Out Coupling check for run out due to eccentricity

• Eccentric run out is the amount the axis of a coupling deviates from the axis of the shaft.

• It is caused by the bore of the coupling being off-centre.

Pre-Alignment Check
Coupling to Shaft Run Out Coupling check for run out due to eccentricity

• Fix the bracket on the skid.

• Fix the dial indicator on the coupling rim almost vertically.

Pre-Alignment Check
Coupling to Shaft Run Out Coupling check for run out due to eccentricity

► Rotate the shaft 360 degree and check the max reading.

Eccentric run out misalignment tolerance

• If the reading was more than 2 mils (0.002”), it is best to replace the coupling.

► When it is not possible to scrap the coupling or align it, you must to re-condition it by
bushing and machining operations.
Pre-Alignment Check
Coupling to Shaft Run Out Coupling check for run out due to eccentricity

• Angular run out occurs when the coupling half is bored at an angle to its axis.

• It is caused by the bore of the coupling being off-centre.

Pre-Alignment Check
Coupling to Shaft Run Out Coupling check for run out due to eccentricity
► How to check angular run out

• Fix the bracket on the skid.

• Fix the dial indicator on the coupling rim

almost horizontally.

• Rotate the shaft 360 degree and check

the max reading.
Pre-Alignment Check
Coupling to Shaft Run Out Coupling check for run out due to eccentricity

Angular run out misalignment tolerance

• If the reading was more than 2 mils (0.002”), it is best to replace the coupling.

► When it is not possible to scrap the coupling or align it, you must to re-condition it by
bushing and machining operations.
Pre-Alignment Check
Check of Pipe Strain

• Suction and discharge pipes shall be

checked.

• Mount the dials on the coupling and loosen

the pipe flange, monitor the dials.

• Any movement greater than 0.002" requires

some corrective action.
Pre-Alignment Check
Check of Pipe Strain
Pre-Alignment Check
Check of Pipe Strain
Pre-Alignment Check
Soft Foot
Pre-Alignment Check
Soft Foot

Hole in the Motor Is Larger Than the Bolt to Allow for Horizontal Movement
Pre-Alignment Check
Soft Foot
Pre-Alignment Check
Soft Foot
Pre-Alignment Check
Soft Foot
Pre-Alignment Check
Soft Foot
How to measure soft foot

Using a feeler gauge to detect soft foot

• Remove all old shims and clean the

drive base and feet.

• Reinstall the driver with hold-down

bolts left loose

• Check each foot by attempting to pass

a feeler gauge under it.
Pre-Alignment Check
Soft Foot
How to measure soft foot

Using a feeler gauge to detect soft foot

• Any foot that does not come in contact

with the base is a soft foot.

• If a 0.003" feeler gauge passes

completely under a foot, determine
the exact amount of gap and place
shims under the foot.

• If a thicker feeler passes only part way

under the foot, an angular Soft foot is
indicated.
Pre-Alignment Check
Soft Foot
How to measure soft foot

Using a dial gauge to detect soft foot in

precision application

• Remove all old shims and clean the

drive base and feet.

• Tighten the hold-down bolts to their

correct torque values.

• Set the dial indicator contact to read

on a mounting foot.
Pre-Alignment Check
Soft Foot
How to measure soft foot

Using a dial gauge to detect soft foot in

precision application

• Slack off the hold-down bolt for that

foot and note the dial reading.

• Repeat this procedure for all

mountings (feet) on the unit.

• Analyze the readings to assess the soft

foot.
Pre-Alignment Check
Soft Foot
How to correct soft foot
Pre-Alignment Check
Soft Foot
Pre-Alignment Check
Other Checks

• Check leveling of the pump skid

• Check tightening on anchor bolts

• Clean the motor base.

• Tighten on the motor bolts

• Check suction and discharge valve in closed position.

• The pump should be electrically isolated.

Pre-Alignment Check
Other Checks
Pre-Alignment Check
Other Checks
Alignment Correction Planes

Horizontal Vertical
(Use Jack Bolts) (Add or remove shims)

Correction
Planes
Alignment Correction Planes
Horizontal Correction
Alignment Correction Planes
Vertical Correction
Pre-Alignment Check
Check of Sag
• Bar sag is simply the effect of gravity on a fixture.
• Sag corrections in dial setting are applied only to rim readings.
Pre-Alignment Check
Check of Sag

How to measure the sag

• Take a straight length of shaft or pipe and support it in a horizontal position so that it can be rotated.

• Mount the dial indicator and its hardware at the same span that it will be at when mounted on the

coupling.

• Rotate the dial to the 6 o’clock (bottom) position and set the bezel to zero.

• Rotate the shaft 180° to the 12 o’clock (top) position:

If there is no sag, the dial reads zero.

If there is sag, the dial has a positive reading.

Pre-Alignment Check
Check of Sag

How to correct the sag

With the dial indicators positioned in

the 12 o’clock position, set the dial bezel

to a plus value equal to the

predetermined amount of sag.

Pre-Alignment Check
Check of Sag

How to correct the sag

Alignment Techniques
Rough Alignment

• A straight edge is placed across the coupling halves to test for parallel misalignment.

• Rough alignment is the primary set in any precision alignment.

Alignment Techniques
Rough Alignment
Alignment Techniques
Rough Alignment
Alignment Techniques
Rough Alignment
Alignment Techniques
Face and Rim Method
• Rim and face alignment is used where the alignment specifications are more critical than in
a rough alignment.
• In this method, dial indicators are used to accurately measure the amount of misalignment
of the shafts.

M P
Alignment Techniques
Face and Rim Method
• Rim and face alignment is used where the alignment specifications are more critical than in
a rough alignment.
• In this method, dial indicators are used to accurately measure the amount of misalignment
of the shafts.
Alignment Techniques
Face and Rim Method Alignment Procedure

• Rotate the bezel to zero both indicators at

the 12 o’clock position. Adjust the rim
reading dial indicator to the pre-
determined sag (plus) values.

• Now rotate the shafts and record both dial

readings at the 3 o’clock (90°), 6 o’clock
(180°) and 9 o’clock (270°) position.

• Check “Top + bottom = Left Side + Right

Side”
Alignment Techniques
Face and Rim Method Alignment Procedure

• Make the reading “zero” at 12 O’clock for vertical alignment for both rim and face.
• Make the reading “Zero” at 3 o’clock for horizontal alignment for both rim and face.
Alignment Techniques
Face and Rim Method Mathematical Model

Vertical Correction
Alignment Techniques
Face and Rim Method Mathematical Model

Horizontal Correction
Alignment Techniques
Face and Rim Method

Pro Cons

• It can be used on large diameter shafts • When used on installations where only

where only one shaft will rotate “for one shaft rotates, errors may occur due

uncoupled alignment”. to roughness of the coupling or shaft.

• It is geometrically accurate when used • There may be difficulties in setting up

on large diameter couplings with short dial indicators to obtain accurate face
spans. readings.
Alignment Techniques
Double Radial Method

Both dials at 12 o’clock.

Take sag in your consideration

Take one turn and check the “Top + Bottom= Left + Right”
Alignment Techniques
Double Radial Method

For Vertical or horizontal alignment

Perform all pre-alignment checks. “Don’t forget sag for vertical alignment”

Mount indicators where the plungers of the indicators at half-way through their travel.

1. Zero the dials at 12 o’clock “or 3” and check the 6 o’clock readings “or 9”.

2. Calculate the shim change “or screws movement” for the vertical alignment “or horizontal”, using the
equation.

3. Both angular and offset alignments are corrected at the same time.
Alignment Techniques
Double Radial Method
Alignment Techniques
Laser Alignment
Alignment Techniques
Laser Alignment

• With the advent of laser technology, alignments can

be achieved to high degrees of accuracy.
• A laser alignment system uses a laser diode to
produce a straight laser beam.
• These beams can be either visible or invisible to
the naked eye.
• The laser beams may be Class 1 (invisible) or Class
2 (visible).
• Looking directly into the laser beam without
protection is not recommended.
Alignment Techniques
Laser Alignment

Advantages of Laser Alignment

• Good for long spans

• Gives consistent, accurate results

• Avoids mistakes in calculation

• Has fast set-up and most system brackets are

easily attached to the machine

• Avoids the problem of bracket sag

Alignment Techniques
Laser Alignment

Disadvantages of Laser Alignment

• The equipment has high initial cost

• Heat sources can have a negative effect on the

accuracy of the beam

• Equipment calibration must be checked

regularly
Alignment Techniques
Laser Alignment

Aligning Motor to Pump

Reading Shows Angular & Parallel Deviation

LASER Aligning Display Unit

Alignment Techniques
Computer Alignment
Alignment Techniques
Computer Alignment
Misalignment Tolerances
Offset Misalignment

So, if we have a 3000 RPM motor

with 6” shaft spacer length; the
permissible offset misalignment
will be not more than:

0.5 * 6 = 3 mils “0.075 mm”

Misalignment Tolerances
Angular Misalignment

So, if we have a 3000 RPM motor

with 2” shaft diameter; the
permissible angular misalignment
will be not more than:

0.38 * 2 = 0.76 mils “0.02 mm”

Motor Sheave – Fan Pulley Alignment
Motor Sheave – Fan Pulley Alignment
Motor Sheave – Fan Pulley Alignment
Motor Sheave – Fan Pulley Alignment
Traditional Alignment
Motor Sheave – Fan Pulley Alignment
Laser Alignment
 Thank you for
your attention!
Any Questions?
Contact Details

Hesham M. Khalil
Tel: 01002729088

Hekhalil@gmail.com