LESSON

HEAT AND ITS EFFECT ON ALIGNMENT

LECTURE
SUB-OBJECTIVE
At the end of this Lesson, the Trainee will be able to describe the effect
of heat on alignment without error.

1.0

INTRODUCTION
The expertise required for aligning machinery is made even more
complicated by the effects of heat. This is called Heat Growth, and needs
to be taken into consideration during alignment operations.

2.0

PREPARATIONS
Before alignment is carried out it is important that all suction and
discharge pipework is connected and other components installed, because
if these are added after the alignment has been carried out it could very
easily throw out the alignment again. The manufacturers specifications
must be checked to see if any vertical difference between the coupling
halves are specified because some equipment heats up as it runs. This is
particularly important where a steam or gas turbine is to be the prime
mover for the pump/compressor etc. This heating can raise the shaft
during running, which is precisely when we require the alignment to be
perfect!

Fig. 15-2-1.
This heat growth has to be taken into account when aligning the machine from
cold. The data for this offset alignment is calculated by the manufacturer and is
included in the handbook.

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3.0

RUN-OUT
Another preparation that has to be checked before alignment can be
carried out is called "Run-out".
This operation checks the concentricity of the shafts/couplings. This
concentricity is checked using a dial indicator. The dial indicator is
mounted on the base plate of the machine and set so that the needle is
reading zero when touching the shaft/coupling. The shaft is rotated and
the indicator observed to see if the permitted amount of deflection is not
exceeded.
Any deflection means that the shaft is distorted or bent. This operations is
similar to the exercise you did in Module 20 during the exercise of
centering your work piece in the lathe chuck using the D.T.I. Time can be
saved by placing the shaft on a precision surface during maintenance work
and checking it out whilst it is still in the workshop using the D.T.I. or even
Feeler Gauges whilst rotating the shaft.
Sketch what you understand by Runout.

4.0

CORRECTING VERTICAL MISALIGNMENT

All vertical misalignment, whether angular or parallel, is corrected by
using shims. Shims are usually pieces of stainless steel or brass that are
placed in pairs under the feet of equipment to correct vertical alignment.
If, the gap at 12 O'clock is greater than that at 6 O'clock, then shims must
replaced under the outboard feet of the motor to correct the vertical
angular misalignment

Fig. 15-2-2
If the problem was vertical parallel misalignment, then equally sized shims would
be placed under all four feet of the motor.

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Fig. 15-2-3.
NOTE:
Since pumps and compressors are connected to pipe work, it is usually
easier to move the motor on its bedplate because the motor is only
constrained by flexible electric wiring. Moving the pump would mean?
There are some guidelines to follow when using shims:

5.0

Shims must always be a big as the foot of the equipment they support. It
is better to use one thick shim rather than several thinner shims Shims
should be clean and free of dirt, grease and paint. The bedplates and feet
of the equipment must be clean and flat. Shims must always be used in
pairs. Otherwise equipment could rock/tilt. Shims must not be liable to
rust or corrode as this would upset the alignment.

CORRECTING HORIZONTAL MISALIGNMENT

Just as both types of vertical misalignment are corrected using shims,

Horizontal Misalignment (both parallel and angular) can be corrected by
moving the motor horizontally on its bedplate. In the case of horizontal
parallel misalignment, the motor is unbolted from its bedplate, and the
whole motor moved sideways.

Fig. 15-2-4.
If the problem is horizontal angular misalignment, the motor is unbolted
and turned horizontally until the centre lines of both shafts meet to form a
continuous straight line.

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Fig. 15-2-5.

NOTE:
To enable the motor to be easily moved in the horizontal plane, the feet of
the motor often have elongated or enlarged bolt holes.

6.0

DOWEL PINS
To ensure that once the motor has been aligned it will not move position
due to vibration etc., and to enable easier alignment after motor removal,
dowel pins are often fitted.
These may be of the tapered or parallel type. The fitting of these pins will
be covered in workshop practical exercises.
Once alignment has been completed, it is now modern practice to cement
around the machinery baseplates, particularly on heavier equipment.

7.0

ALIGNING BELT DRIVEN MACHINERY

Belt driven machinery is much easier to align because of its geometry, and
because of a greater tolerance of its precision requirements.

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Fig. 15-2-6. Arrangement of motor slide rails.

8.0

TENSION SETTING
However, the setting of the tension of the belt is an operation that needs
to be done accurately, and to the manufacturers specifications if long life
of the bearings and belt are to be expected. This operation needs to be
done when adjusting the belts on the air conditioning compressor,
alternator and power steering pump of your car!

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Fig. 15-2-7.
Examples of Uses of D.T.I.'s in Alignment Operations.
There are many methods of taking alignment readings, and calculating
rectification corrections having obtained the readings by D.T.I., but they
fall outside of the scope of this Module.
Indeed, Specialist Advanced Courses are required to learn some of the
different methods than can be used.
The preparations for setting up the special brackets that are sometimes
needed can be very time consuming.
Some of the brackets themselves introduce more complications to the
alignment operations because they can introduce "Sag" into the
calculations.
However, following are some figures that can give you an idea as to what
can be involved when carrying out an alignment operation.
Your Instructor will give you a brief explanation as to the following
methods of alignment using a D.T.I.
Fig. 15-2-8. shows a D.T.I. attached to the shaft with a magnetic clamp.

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Fig. 15-2-8.
Fig. 15-2-9 shows the different position the D.T.I. takes as it moves up and
down, and rotates around a shaft. You can imagine the deflection of the
needle on the dial face as it is moved about.

Fig. 15-2-9.
Fig. 15-2-10 shows a method of alignment called the Face and Rim Method.

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Fig. 15-2-10.
The method requires special brackets and the use of two dial indicators.
The distances between the motor pedestal feet and the coupling half
needs to be known as well as other measurements. Using special
equations the required adjustments for perfect alignment can be
calculated.

Fig. 15-2-11.
Another method known as Reverse Dial Indicator can be used as shown in Fig.
15-2-12 below.

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Fig. 15-2-12.
This method also requires the use of special brackets and two DTI's. The
alignment adjustment required can either be calculated using a formula, or
it can even be done by using a geometric scale drawing on good quality
graph paper.
Some alignment operations can taken days and even weeks to get perfect,
but it is worth it in the end because the functional life of the machinery
can meet its design specifications if done correctly.

9.0

END FLOAT
There is one other aspect of alignment that has not been mentioned yet,
and that is End Float.
It is all very well aligning two shafts perfectly so that their centre lines are
continuous, but it must not be forgotten that Axial Alignment is also very
important.
In many cases it is vital that there is some room for axial expansion of the
shafts.
This Axial Clearance is also very important for the Thrust Bearings of the
machinery.

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Fig. 15-2-13.
The Manufacturers specifications must be consulted
recommended End Float Clearance can be set correctly.

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so

that

the

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QUESTIONS:
1.

Name three precision alignment instruments

2.

How can heat affect alignment?

3.

How do you compensate for heat when aligning from cold?

4.

What does a "Runout reading tell you?

5.

Name four guide lines to be used when using Shims.

6.

How is vertical misalignment corrected?

7.

How is horizontal misalignment corrected?

8.

Why are Dowel pins used?

9.

On a belt driven machine, what would be the effect if the belt tension was:
a.
b.

Too low
Too high

10.

Name two methods of taking alignment readings using D.T.I.'s

11.

What is "Sag"?

12.

What is End Float?

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