ALIGNMENT

PROCEDURE

Rakesh Shah
Condition Monitoring

What is Misalignment?

It is deviation of relative shaft position from collinear axis of
rotation when equipment is running at normal operating
condition.

What is alignment?

A procedure by which driver & driven shafts are made
collinear with axis of rotation.
 Alignment-Some facts

Out of every 100 failures / breakdowns in rotating machines due to
mechanical reasons, about 50 are caused by misalignment & about 40
are caused by unbalance / other issues. This has been revealed by
studies carried out throughout the world.

Thus misalignment is the single largest sources of rotating machinery

problems like bearing failure, mechanical seal failure, shaft failure,
coupling failure etc.

The reason why misaligned machinery continuous to exist is that there

is a general lake of awareness of the importance of precise alignment.
This has given rise to several misconceptions in the minds of people
regarding alignment.
 Effects of Misalignment

Uneven load on bearings. Due to high load,
premature bearings failure occurs.

It breaks lubricant film inside the bearing & increases
friction.

It increases operating temp of bearing housing &
leads to oil/grease degradation.

Misalignment increases 2-17% power consumption.

Coupling element failure rate increases.

Vibration. It affects critical parts of machine like
bearings, seal, coupling, gears etc.
 When to do Alignment check

When new equipment (shaft coupled equipment) is being
installed.

After doing such repair work which disturbs shaft /
bearings / casing / housing.

Whenever vibration indicates the need.

Periodically on critical / semi critical equipments (PM).
 Indications of Misalignment

Excessive radial and axial vibration.

Premature bearing, seal, shaft and coupling failure.

High bearing/bearing oil temperature.

Repetitive failure of seals.

Coupling is hot while running.

Premature failure of coupling.

Loose foundation bolts/loose coupling elements.

Shaft breaking at/close to inboard bearings.

Similar pieces of equipment are vibrating less &
have longer operating life.
 Types of Misalignment

Parallel or Radial or offset

Angular or Axial

Combination of
Radial + Axial (Skew)
 How to do Alignment
*Alignment methods*

Approximate or rough alignment

Precision alignment

• For the critical / semi critical machines we handle at GFL,

approximate or rough alignment is not recommended.
• For good machine life only precision alignment is
preferable.
• However, if misalignment is high & very obvious, it will be
good practice to do rough alignment before starting
precision alignment.
Approximate / rough alignment methods

By use of straight edge, taper gauge & filler gauges

Using straight edge & filler gauge, top & bottom coupling
gap can be measured & adjustment can be done accordingly.

Requirements:
1. Coupling surface should be smooth.
2. Coupling bore should be true (concentricity & angularity)
3. Coupling halves OD should be same.
 IMPORTANT CONSIDERATIONS BEFORE STARTING ALIGNMENT

Make sure that run-out at the shaft as well as at coupling is less than 0.05 mm on both
the machines. See figure

Run-out should not exceed 0.05 mm

Decide which machine will be kept stationary and which one will be moved. Generaly, for a motor pump
combination, pump is kept stationary, for a turbine pump combination, turbine is kept stationary. In general,
driven machine kept stationary.

Check for rusty, deformed or broken shims/too many shims under the support legs. Number of shims should
not exceed four.

Make provision for moving the machinery (both sidewise and updown motion). For sidewise motion, using
jack bolts is the preferred method. For up-down motion , wedging at the appropriate place is done and then
shims are kept below the legs.
 Alignment procedure (taking alignment readings) – Step no. : 1

L1
L2

Dial pointer should preferably be kept on the machine to be moved.

The sum total of both side readings should be same as sum total of top bottom readings. In actual practice, we
can allow a difference of about 15%. This rule is called validity rule.

Sum total of side readings = 0.15 + 0.25 = 0.40

0.00 Sum total of top bottom readings = 0.00 + 0.36 = 0.36
Difference = 0.40 – 0.36 = 0.04
For R This difference should be less than 15 %
Example 0.15 0.25 15 % of 0.40 = 0.06
Thus difference is less than 15 %. hence alignment reading is valid.
0.36

Important :

Alignment correction should be attempted only when Sum total of side readings and top bottom readings are
Matching within 15 % as shown in the above example.
What checks to do if alignment readings are found invalid :

Check the clamp for looseness. If found loose, tighten.

Check the dial pointer is leaving contact during rotation. If so, do rough
alignment with straight edge first.

Check the coupling for eccentricity and shaft for run-out. Rectify and rotate
both shafts together.

If still alignment readings are found invalid, it means that there is sag in the
dial clamp.
 ALIGNMENT PROCEDURE – STEP NO. : 2
SAG MEASUREMENT AND CORRECTION
IMPORTANT :
This step is to be carried out only if the sum total of side readings is not matching
with the sum total of top-bottom readings.

WHAT IS SAG ? SEE FIGURE

6 O’CLOCK

12 O’CLOCK

When dial is at 12 o’clock position, the clamp bends towards the coupling.

When the dial is at 6 o’clock position the clamp bends away from the coupling.

This movement of clamp causes change in dial readings. Due to this change, sum total of top-bottom
readings does not match with sum total of side readings. This effect is called sag.
 Alignment procedure – step no. : 3

How to remove sag error from the alignment readings :

Measure the value of sag with the help of
Sag measurement setup as shown in
figure.

This sag value will be negative.

Add the sag value to the alignment readings

As shown in the following example.
0.00

+ 0.12 + 0.12
FOR EXAMPLE ALIGNMENT READING IS

As we can see, sum total of top-bottom readings + 0.16
& Side readings is not matching. All three checks,
Given in step no.:1 have been done. Still difference is coming 0.00

Dial readings from the sag measurement setup are as follows.

It means there is sag of 0.08 mm. - 0.08

This sag value will be added to the alignment
Reading of 12 o’clock position after changing + 0.08
The sign from minus to plus. Modified reading
Is as follows : + 0.12 + 0.12

+ 0.16

Now, sum total of side readings and top bottom readings s matching. Now, we can proceed to step
no. : 3 of alignment procedure.
 ALIGNMENT PROCEDURE – STEP NO. : 4
CALCULATING MACHINERY MOVEMENT

IMPORTANT :

For best results, radial and axial alignment corrections should be done together. A
table for this purpose is shown as follows :

AMOUNT OF SHIMS REQUIRED AT

FRONT LEG REAR LEG
FOR RADIAL ALIGNMENT A mm A mm

FOR AXIAL ALIGNMENT B mm C mm

FOR TOTAL ALIGNMENT CORRECTION A + B mm A + C mm

 ALIGNMENT PROCEDURE – STEP NO. : 4A
CORRECTING RADIAL MISALIGNMENT

Radial correction value is half of the total indicator reading.

0.00
FOR EXAMPLE :

+ 0.20

Dial is clamped on pump coupling and pointer is on motor coupling.

Dial is set to zero at 12 o’clock position.

Dial is reading +0.20 mm AT 6 O’CLOCK POSITION.

This means that motor shaft is down (+ sign means dial pointer has got compressed.)

Thus motor shaft will have to be lifted up by +0.20/2 = 0.10 mm . That is, shimming of 0.10 mm Is
required at all the four legs.

Important :
For radial misalignment correction, the value of shimming required will be same for
all the four legs, as we saw in the above example.
 ALIGNMENT PROCEDURE – STEP NO. : 4B
CORRECTING AXIAL MISALIGNMENT
SEE FIGURE :

L1
L2

D = Diameter on which the dial is moving. ( Approx. equal to coupling diameter).

L1 = Distance at front leg from motor coupling.

L2 = Distance at rear leg from motor coupling.
shimming required at front / back leg = L1 or L2 x dial reading / D
0.00

EXAMPLE :

+ 0.30

Diameter of dial travel D = 100 mm

Distance of front leg to coupling L1 = 200 mm

Distance of rear leg to coupling L2 = 400 mm
Now, dial is set to zero at 12 o’clock position. Dial reads + 0.30 at 6 o’clock position
This means that top gap between couplings is more than bottom gap (+ sign means dial pointer has
got compressed)
 ALIGNMENT PROCEDURE – STEP NO. : 4B
CORRECTING AXIAL MISALIGNMENT
SEE FIGURE :

Thus motor shaft will have to be lifted up.

Shimming required at front leg = L1 x dial reading / D

= 200 x 0.30 / 100
= 0.60 mm

Shimming required at back leg = L2 x dial reading / D

= 400 x 0.30 / 100
= 1.20 mm

IMPORTANT :
For axial misalignment correction, the amount of shims required to be added or
removed is different for the front legs and back legs.
 ALIGNMENT PROCEDURE – STEP NO. : 4C
CORRECTING TOTAL MISALIGNMENT

As per our example, the top bottom readings are :

0.00 0.00

R A

0.20 mm 0.30 mm

Shiming required for radial & axial misalignments respectively have been calculated on the previous slides.
The total shiming required is calculated as follows :

AMOUNT OF SHIMS REQUIRED IN

FRONT LEG REAR LEG
TO CORRECT RADIAL ALIGNMENT + 0.10 mm + 0.10 mm

TO CORRECT AXIAL ALIGNMENT + 0.60 mm + 1.20 mm

TOTAL ALIGNMENT CORRECTION 0.10 + 0.60 = 0.70 mm 0.10 + 1.20 = 1.3 mm

Thus, in order to do total (radial + axial ) alignment, put shims of 0.70 mm in front leg and 1.3 mm in back leg
of motor in our example.
 ALIGNMENT PROCEDURE – STEP NO. : 5
MOVING THE MACHINERY

For top-bottom movement shims are added or removed from below the feet of the machine to be
moved. For this purpose, the machine is lifted up by wedging, and then shims are added or removed.

For side wise movement, using jack bolts is the preferred method. A light hammer can also be used
on small machines. The movement should be closely monitored by two dial gauges, as shown in the
figure.

IMPORTANT :
After making the required movement, one final alignment reading should be taken.
 CONCLUSION
Which alignment to do first : Top-Bottom or Sideways alignment?

We have to see that it is very convenient to do radial and axial alignment correction
together.

Hence, we can say that ultimately there are only two types of misalignments – top-
bottom (radial + axial) misalignment and side wise (radial + axial) misalignment.

For best results top-bottom alignment should be done first, followed by side wise
alignment. The reason is that if you do side wise alignment first, then while doing top-
bottom alignment, side wise alignment will again get disturbed.

How ever, if during step no.: 1 (taking alignment readings) it is found that side wise
misalignment is very large as compare to top-bottom misalignment, then rough
alignment (of side wise) should be done first. After that final top-bottom alignment and
then final side wise alignment should be done.
Do’s and Don’ts of moving machinery

DO’S

Place a thin film of lubricant under the foot points.

Needle nose pliers (not fingers) should be used to remove or add the shims under the feet.

Consider removing shims instead of adding them.

Use single-thickness plate/s instead stacking many plates.

Place shims under one side or foot at a time when making vertical moves to prevent the machine from
loosing the sideways alignment.

Radius the outside corners of thin shims stock to prevent them from folding over during installation.

When tightening the foundations bolts, have dial indicators positioned along the side of each unit to
determine the unit is moving back out of alignment.

Apply the same amount of torque to the foundation bolts after each vertical and / or laterals move
before taking another set of alignment readings

Check the torque on all foundations bolts after completing the alignment job.

Don’ts

Use pipe wrenches to rotate shafts or move equipment.

Use coupling bolts slid into the coupling hub holes and a bar to rotate a shaft for
alignment readings.

Use carbon steel shim stock.

Use a hammer to install shims under the machinery feet.

Install shims that have paint anywhere on the surfaces of the shim.

Use a large number of thin shims to make a thick spacer under a foot.

Summary of overall alignment jobs

1. Identify machinery to be aligned and relevant information on machine elements, coupling

etc. Use machinery data card as reference.

2. Inspect machinery foundation and base plate for damage or problem areas. Plan
necessary repairs or fixes during shutdown. Measure vibration levels and vibrations
signatures of the equipment.

3. Train maintenance or contractor personnel on proper alignment measuring methods,

machinery movement devices and procedures, checks for static movement casings
obtaining cold alignment readings, use and care of dial indicator and micrometers, and
allowable misalignment tolerances.

4. Purchase necessary tools and measuring devices. Fabricate alignment brackets,

jackscrews and lifting mechanisms. Measure bracket sag. Shut equipment down and take
necessary precautions to prevent starting driver unit and secure driven unit to prevent
reverse rotation etc.

----Contd.....
Summary of overall alignment jobs
5. Remove coupling guards and coupling spool piece if necessary. Measure the shaft and
coupling hub run out on both units. Inspect coupling for any damage or worn parts.
Keep track of the coupling parts and label them if necessary. If equipment is going to be
removed for servicing, make punch marks on casing and base plate as a reference
during reinstallation.

6. Check for soft foot, casing or frame warpage, excessive static piping or conduit forces,
damaged or rusty shims, loose foundation bolts etc. Correct any of the potential problem
areas.

7. Take and record a set of alignment readings.

8. Calculate and perform the necessary axial, vertical and horizontal move. Recheck
alignment, calculate and move until equipment is within acceptable alignment
tolerances. Torque foundation bolts to required values. Record final alignment readings.

9. Install coupling and torque bolts to required values and install coupling guard. Check for
rotational freedom of entire drive train if possible.

10. Operate unit at normal conditions checking and recording vibrations levels, bearings
temperatures and other pertinent operating parameters.
 Next generation alignment-
Laser alignment system

Easy to use. No practice required.

Basic principle is reverse indicator
method.

Tedious calculations done by m/c
itself.

No indicator sag. Linkage replaced
by optical beam.

Readings not affected by axial
float.

Good resolution.
 Laser alignment system-Principle

Consists of two transmitter & detector units and one display
unit .

One TD unit is mounted on each shaft.

Readings are obtained by generating a coherent beam from
an infrared emitting semiconductor laser and reflected back
into detector via a prism.

An efficient software is attached to system which can calculate
shimming correction under each foot.

Before starting alignment shaft height, coupling dia., distance
of front & rear foot is fed into software as input data.

After shimming correction final check is made.

No need of 360 degree shaft rotation.
 V-Belt Alignment

Alignment is not critical

Proper alignment is essential

First make sure that drive shafts are parallel.

Common causes/effects of misalignment:

Where shafts are not parallel, belts on one side are drawn tight and pull
more than their share of the load. This belts wear out faster.

If misalignment is in the sheave belts will enter and leave the groove at an
angle, causing excessive belt and sheave wear.
 V-Belt Alignment

Shaft alignment can be checked by measuring the distance between the shafts at three or more
locations. If the distances are equal then the shafts will be parallel.

To check the location of the sheaves on the shafts, a straight edge or a piece of string can be used as
shown in figure :

CORD TIED
TO SHAFT

CORD TOUCHING SHEAVES AT

POINT INDICATED BY ARROWS

If sheaves are properly lined-up, the string will touch them at the points indicated by the arrow in the
accompanying sketch.

Rotating each sheave a half revolution will determine whether the sheave is wobbly or the drive shaft
is bent.

Correct any misalignment.

 V-Belt Alignment
• Belt Tension Gauge

•Setting Force calculation:

Questions ????