iLearnAlignment

Alignment Training Subjects

The following is a list of the subjects covered in the iLearnAlignment training system. The
complete detail is shown.

Alignment Fundamentals - An Introduction

ƒ Introduction to Shaft Alignment
ƒ Introduction
ƒ Why is misalignment so important?
ƒ Bearing damage
ƒ Seal damage
ƒ Coupling damage
ƒ Vibration
ƒ Energy consumption
ƒ Product quality
ƒ Downtime and production capacity
ƒ Detecting misalignment
ƒ What is misalignment?
ƒ What is misalignment?
ƒ A closer look at misalignment
ƒ Shaft fatigue
ƒ Even bent shafts have rotational centerlines
ƒ Offset and angular misalignment
ƒ Alignment conventions
ƒ Specifying misalignment
ƒ Using feet corrections to specify misalignment
ƒ Using Total Indicator Readings to specify the misalignment
ƒ Using offset and angularity to specify alignment targets
ƒ Angularity targets
ƒ Visualizing tolerance
ƒ Tolerances and speed
ƒ Spacer couplings (jack shafts) conventions and tolerances
ƒ Published tolerances
ƒ Dynamic movement
ƒ Pre-Alignment checks and soft foot
ƒ Pre-alignment tasks
ƒ Determining the alignment state
ƒ Determining the alignment state
ƒ Using a straightedge or feeler gauge
ƒ Using dial indicators
ƒ The Rim and Face method
ƒ The Reverse Dial method
ƒ Reverse dial method
ƒ Dial indicator limitations
 ƒ Laser alignment systems
ƒ Laser alignment systems
ƒ Moving the machine
ƒ Moving the machine vertically - shimming
ƒ Moving the machine laterally
ƒ Summary

Shaft Alignment Mathematics - A Primer

ƒ Offset, angularity and alignment mathematics
ƒ Introduction
ƒ Equal triangles
ƒ Triangles and alignment
ƒ A triangle from two offsets
ƒ Dealing with negative numbers

Understanding Dial Indicators

ƒ Dial indicators
ƒ Introduction
ƒ What can go wrong?
ƒ Zero the dial
ƒ Bar sag
ƒ Total Indicator Readings (TIR)
ƒ Hysteresis
ƒ Clock positions
ƒ Backlash
ƒ Why do we rotate both shafts?
ƒ Using dial indicators for shaft alignment
ƒ Using dial indicators for shaft alignment
ƒ Rim measurements
ƒ Face measurements
ƒ Axial end-play and float
ƒ Repeat all tests
ƒ Validity rule

Pre-Alignment Checks and Corrections

ƒ Pre-alignment Checks
ƒ Introduction
ƒ Plan and review maintenance history
ƒ Why is the machine not aligned?
ƒ Installing a new machine
ƒ Decide on the required tolerance and coupling gap
ƒ Pipe strain
ƒ Mechanical looseness
ƒ Bent shafts and coupling runout
ƒ General preparations on site: Safety
ƒ General preparations on site: Clean up
ƒ General preparations on site: Shims
ƒ General preparations on site: Jacking bolts
Soft Foot Checks and Corrections
ƒ Detecting and Correcting Soft Foot
ƒ Introduction
ƒ Different types of soft foot
ƒ Rocking soft foot
ƒ Short foot - parallel air gap
ƒ Even foot
ƒ High foot
ƒ Bent foot
ƒ Squishy foot
ƒ Induced soft foot
ƒ Why is soft foot important?
ƒ Why is soft foot important?
ƒ Shaft fatigue
ƒ Bearing distortion
ƒ Impact on the alignment task
ƒ Testing for soft foot
ƒ Testing for soft foot
ƒ Taking soft foot measurements
ƒ Recording results
ƒ Using dial indicators to measure soft foot
ƒ Correcting soft foot
ƒ Correcting rocking soft foot
ƒ Short cut number one: The Casanova method
ƒ Short cut number two: The 80% Rule
ƒ Using feeler gauges
ƒ Using a "stair" of shims
ƒ More complex shim patterns
ƒ Detecting and correcting induced soft foot
ƒ Mysterious soft foot
ƒ Summary

The Rim-Face Dial Indicator method

ƒ The Rim-Face dial indicator method
ƒ Introduction
ƒ What if only one shaft can be rotated?
ƒ Accuracy issues
ƒ Setup problems
ƒ Axial end-float
ƒ Rim-Face Measurement Procedure
ƒ Compensate for bar sag
ƒ Alternative method
ƒ Determine the alignment corrections
ƒ Performing the calculations
ƒ Computing the offset
ƒ Computing the angularity
ƒ Computing feet movements
ƒ Shim calculations
ƒ Move calculations
ƒ Example calculations
 ƒ The graphical method
ƒ Summary

The Reverse-Dial Method

ƒ The Reverse Dial method
ƒ Introduction
ƒ Reverse dial procedure
ƒ Compensate for bar sag
ƒ Performing the calculations
ƒ Computing the offset
ƒ Computing the angularity
ƒ Computing feet movements
ƒ Shim and move calculations
ƒ An example
ƒ Example:
ƒ The graphical method
ƒ Summary
ƒ Alternative method

Laser Alignment
ƒ Laser alignment systems
ƒ Introduction
ƒ The basic components in a laser alignment system
ƒ Benefits of laser alignment systems over dial indicators
ƒ How do laser alignment systems work?
ƒ Using a Prism - Return Beam Method
ƒ Beam Splitter - Single Beam Method
ƒ Twin Emitter/Detector Pairs - Dual Beam Method
ƒ Using a horizontal beam and a vertical detector
ƒ Using the laser alignment system
ƒ Performing the laser alignment
ƒ Pre-alignment
ƒ Preparing the coupling
ƒ Attaching the brackets
ƒ Attach the brackets
ƒ Check the optics
ƒ Mount the laser heads
ƒ Aim the heads
ƒ Zeroing the beam
ƒ Check for repeatability
ƒ Rough alignment ("roughing-in")
ƒ Correcting gross angularity
ƒ Correcting gross parallel offset
ƒ Dealing with gross misalignment
ƒ Rough alignment with a laser system
ƒ Dealing with distance and angularity
ƒ Cones and circles and distance
ƒ Enter the machine dimensions
ƒ How accurate should the dimensions be?
ƒ Entering the coupling diameter
 ƒ Performing laser alignment measurements
ƒ Performing the measurements
ƒ The 3:00-12:00-9:00 method
ƒ Swept measurements
ƒ Getting the results
ƒ Aligning spacer shafts or jackshafts
ƒ What if you can't rotate one shaft?
ƒ What if the shaft can't be rotated easily?
ƒ What if you can't rotate either shaft?
ƒ Limitations of laser systems
ƒ Backlash
ƒ Vibration
ƒ Heat, steam, sunlight, water vapor
ƒ General comment about commercial systems

Moving the Machine

ƒ Moving the machine
ƒ Introduction
ƒ Perform the vertical move first
ƒ Gross misalignment
ƒ Using a laser alignment system
ƒ Moving the machine vertically - shimming
ƒ Base bound and bolt bound
ƒ Base bound
ƒ Machine the feet
ƒ Moving the machine horizontally
ƒ Using a dial indicator to measure the horizontal move
ƒ Using shims to measure horizontal machine moves
ƒ Bolt bound
ƒ Turn-down the bolts
ƒ Open the bolt holes of the machine feet
ƒ Moving the stationary machine
ƒ Drill new holes

Dynamic and Thermal Movement

ƒ Dynamic and Thermal Movement
ƒ Introduction
ƒ Which machines will be affected?
ƒ Thermal effects
ƒ Manufacturer's supplied offsets
ƒ Sources of heat
ƒ Internal or system sources of heat
ƒ External sources of heat
ƒ Mechanical effects
ƒ Pipe strain
ƒ Oil wedges
ƒ Jacking fluid
ƒ Catenary sag
ƒ Foundation changes
 ƒ Dealing with dynamic movements
ƒ Dealing with dynamic movements
ƒ Temperature compensation
ƒ Take 'hot' readings
ƒ Monitoring the movement of the shaft or bearings
ƒ Using laser heads to measure relative movement
ƒ Issues to consider
ƒ General issues to consider
ƒ What do you do with the offset data?
ƒ Manufacturer's offset data
ƒ Determining targets graphically
ƒ Summary

Machine Train Alignment

ƒ Machine Train Alignment
ƒ Introduction
ƒ Repeat your measurements
ƒ Plan ahead
ƒ Graphical method
ƒ Optimizing the alignment
ƒ Movement limitations
ƒ Move in the vertical direction first
ƒ Summary