Alignment

Prepared By :
Hossam Mohamed Abdelrahman
❑ Shaft alignment is the process of ensuring that the rotational axes of two or more shafts are
co-linear and properly positioned. It involves positioning rotating machinery, such as pumps,
motors, compressors, and turbines, so that their shafts are aligned within specified
tolerances.

❑ Proper shaft alignment is crucial for the smooth operation of rotating equipment. Misalignment can lead
to increased vibrations, excessive wear, reduced efficiency, and ultimately, equipment failure. It can
cause damage to bearings, seals, couplings, and other components, resulting in downtime, repair costs,
and production losses.

❑ Shaft alignment is typically performed using tools such as dial indicators, straight edges, feeler gauges, or
laser alignment systems. The process involves measuring the initial misalignment, making adjustments
by shimming or moving machine components, and verifying the alignment until it falls within the
acceptable tolerances
Types of misaliment
❑ Parallel (Offset) Misalignment: Occurs when the centerlines of two shafts are parallel but
not co-linear, meaning they are offset from each other. This can happen in the horizontal
plane, vertical plane, or both.
❑ Angular Misalignment: Occurs when the centerlines of two shafts intersect at an angle rather
than being perfectly aligned.
There are two types:
1. Horizontal Angle Misalignment: The angle between the shafts is in the horizontal plane.
2. Vertical Angle Misalignment: The angle between the shafts is in the vertical plane.
❑ Combined Misalignment: A combination of parallel and angular misalignment:
1. Horizontal Angled and Offset Misalignment: Includes both horizontal angle and parallel
misalignment.
2. Vertical Angled and Offset Misalignment: Includes both vertical angle and parallel misalignment
 Effects OF
MISALIGMENT
1. Excessive Vibration: Misalignment is a leading cause of excessive vibration in rotating
equipment. This increased vibration can lead to premature failure of bearings, seals, and other
components.
2. Premature Failure of Bearings and Seals: Misalignment puts excessive stress and force on
bearings and seals, causing them to wear out much faster than they should.
3. Increased Energy Consumption: Misaligned machinery operates less efficiently, requiring more
energy to run and resulting in higher operating costs.
4. Overheating: Misalignment can cause machinery to overheat, leading to lubrication issues and
safety risks.
5. Shaft Breakage: In severe cases, misalignment can cause the shafts to crack or break, leading
to catastrophic equipment failure.
1. Higher Maintenance Costs: Misalignment results in more frequent breakdowns, unplanned
downtime, and the need for equipment replacement, all of which increase maintenance and
operating costs.
2. Reduced Product Quality: Misaligned machinery can produce inferior or defective products,
impacting profitability.
Alignment states
 Cold Alignment
1. Performed when the equipment is not operating and at ambient temperature
2. Establishes the baseline for the alignment that will be achieved when the equipment is
running at normal operating temperatures
3. Techniques like "reverse indicator graphical plotting" are used to measure and adjust the
initial misalignment before startup
4. Factors like warped foundations, soft foot conditions, and thermal variations can affect the
cold alignment
 Hot Alignment
1. Performed when the equipment is running at normal operating temperatures
2. Verifies if the thermal growth targets used for the cold alignment were accurate
3. Requires quickly shutting down, locking out, and taking measurements to capture the hot
alignment before the machine cools down
4. Hot alignment checks will not capture the initial movement and cooling that occurs in the first
5-30 minutes after shutdown
5. Hot alignment practices have been proven to produce inaccurate results due to this initial
movement
❑ The main advantage of hot alignment is verifying the
accuracy of the thermal growth targets used for cold
alignment. However, hot alignment is prone to
inaccuracies due to the time required to take
measurements after shutdown. Achieving good cold
alignment is a necessary first step, but hot alignment
checks and adjustments are also required to account for
thermal growth and ensure optimal alignment during
operation.
Alignment Method
❑ Straight Edge and Feeler Gauge Method:
1. Uses a straight edge and feeler gauges to measure the misalignment between the two shafts
2. Involves placing the straight edge against the coupling faces and using feeler gauges to
measure the gap at multiple points
❑ Rim and Face Method:
1. Uses a dial indicator to measure the relative displacement between the faces of the two
couplings
2. The dial indicator is mounted on a base attached to one coupling, with the stylus positioned
against the face of the other coupling
❑ Reverse Dial Indicator Method:
1. Uses two dial indicators, each mounted on one of the shafts
2. The indicators measure the relative movement of the shafts at multiple points as they are rotated
❑ Laser Alignment:
1. Utilizes laser-based measurement systems to determine the alignment condition
2. A laser transmitter is attached to one shaft, emitting a laser beam, while a receiver is
attached to the other shaft
3. The laser beam's position is detected by the receiver, and the misalignment values are
calculated by the alignment system
❑ Computerized Alignment Systems:
1. Combine the benefits of laser or optical alignment methods with advanced software
2. Use sensors and detectors to measure misalignment and provide real-time feedback and
graphical representations
3. Often include automated adjustment calculations and recommendations for achieving the
desired alignment