For all mechanical engineers

1. Shaft Alignment
Hassan Mohamed A. M. Hassan
Lead Mechanical Engineer
Worley Parsons Engineers Egypt Ltd.
Cairo Egypt 01223190213
Tel.: +2-02-22706178
Email hasmonem@gmail.com

2. Hassan
Couplings Alignment to determine the
accurate misalignment figures)
1- What is shaft alignment
2- Types of Couplings
3- Alignment Preparation check list
4- Preparation on Alignment
5-How to Do Alignment
6- Reversal Alignment calculation Method
7- Reversal Alignment Graphical Method
(complete with software)
8- Case Studies For Alignment Failure

3. Hassan
Reliability from different perspective
• Centrifugal Compressor Fail to start
• Centrifugal Compressor Alarm and shutdown
Actual Workshop Alignment procedure

4. • Types of Couplings
• Alignment Preparation check list
• Preparation on Alignment
• How to Do Alignment
• Isolation Standard
• (Software for Pumps Alignment Calculations)
• Post assessment
Rotating Equipment Alignment (One of the most cause of failure)

5. It is collinear of two center lines
1-Is the proper positioning of the shaft centerlines of
the driver and driven components.
2-Alignment is accomplished either
A- Shimming
B- Moving a machine component.
Its objective is to obtain a common axis of rotation at
operating equilibrium for two coupled shafts or a train
of coupled shafts.
Rotating Equipment Alignment (One of the most cause of failure)

6. Shafts must be aligned as perfectly as possible
to maximize equipment reliability and life,
particularly for high-speed
It is important because misalignment can introduce
1-High level of vibration
2-Cause bearings to run hot
Proper alignment
1-Reduces power consumption and noise level
2-Helps to achieve the design life of bearings,
seals, and couplings.
Why it is important to make shaft alignment?

7. What is shaft alignment?
Shaft alignment is the positioning of the rotational centers of two or more shafts such
that they are co-linear when the machines are under normal operating conditions.
Proper shaft alignment is not dictated by the total indicator reading (TIR) of the
coupling hubs or the shafts, but rather by the proper centers of rotation of the shaft
supporting members (the machine bearings).
There are two components of misalignment—angular and offset.
Offset misalignment, sometimes referred to as parallel misalignment, is the distance
between the shaft centers of rotation measured at the plane of power transmission.
This is typically measured at the coupling center. The units for this measurement are
mils (where 1 mil = 0.001 in.).
Angular misalignment, sometimes referred to as “gap” or “face,” is the difference in
the slope of one shaft, usually the moveable machine, as compared to the slope of
the shaft of the other machine, usually the stationary machine. The units for this
measurement are comparable to the measurement of the slope of a roof (i.e.,
rise/run). In this case the rise is measured in mils and the run (distance along the
shaft) is measured in inches. The units for angular misalignment are mils/1 in.
As stated, there are two separate alignment conditions that require correction. There
are also two planes of potential misalignment—the horizontal plane (side to side) and
the vertical plane (up and down). Each alignment plane has offset and angular
components, so there are actually four alignment parameters to be measured and
corrected. They are horizontal angularity (HA), horizontal offset (HO), vertical
angularity (VA), and vertical offset (VO).

8. Shaft alignment tolerances
Historically, shaft alignment tolerances have been governed by the coupling
manufacturers’ design specifications. The original function of a flexible
coupling was to accommodate the small amounts of shaft misalignment
remaining after the completion of a shaft alignment using a straight edge or
feeler gauges. Some coupling manufacturers have designed their couplings to
withstand the forces resulting from as much as 3 degrees of angular
misalignment and 0.075 in. (75 mils) of offset misalignment, depending on
the manufacturer and style of the coupling.
Another common tolerance from coupling manufacturers is the gap tolerance.
Typically this value is given as an absolute value of coupling face TIR (as an
example, a specification migh read “face TIR not to exceed 0.005 in.”). This
number can be deceiving depending on the swing diameter of the face dial
indicator or the diameter of the coupling being measured. In fairness, it
should be noted that the tolerances offered by coupling manufacturers are to
ensure the life of the coupling with the expectation that the flexible element
will fail rather than a critical machine component.

9. Shaft alignment is the positioning of the rotational centers of two or more shafts such
that they are co-linear when the machines are under normal operating conditions.
Proper shaft alignment is not dictated by the total indicator reading (TIR) of the
coupling hubs or the shafts, but rather by the proper centers of rotation of the shaft
supporting members (the machine bearings).
There are two components of misalignment—angular and offset.
Offset misalignment, sometimes referred to as parallel misalignment, is the distance
between the shaft centers of rotation measured at the plane of power transmission.
This is typically measured at the coupling center. The units for this measurement are
mils (where 1 mil = 0.001 in.).
If this angular tolerance was applied to a 5 in. diam coupling, the angular alignment
result would be 1 mil/1 in. of coupling diameter or 1 mil of rise per 1 in. of distance
axially along the shaft centerline. If the coupling was 10 in. in diameter, the result of
the alignment would be twice as precise (0.5 mil/1 in.). This would lead one to
conclude that an angular alignment tolerance based on mils/1 in. would be something
that could be applied to all shafts regardless of the coupling diameter.

10. Harmonic forces are dangerous
When shafts are misaligned, forces are generated. These forces can produce great
stresses on the rotating and stationary components. While it is probably true that the
coupling will not fail when exposed to the large stresses as a result of this gross
misalignment, the bearings and seals on the machines that are misaligned will most
certainly fail under these conditions. Typically, machine bearings and seals have small
internal clearances and are the recipient of these harmonic forces, not unlike constant
hammering.
Excessive shaft misalignment, say greater than 2 mils for a 3600 rpm machine under
normal operating conditions, can generate large forces that are applied directly to the
machine bearings and cause excessive fatigue and wear of the shaft seals. In extreme
cases of shaft misalignment, the bending stresses applied to the shaft will cause the
shaft to fracture and break.
Bearing life expectancy
The most prevalent bearings used in machinery, ball and roller bearings, all have a
calculated life expectancy, sometimes called the bearing’s L-10 life— a rating of
fatigue life for a specific bearing. Statistical analysis of bearing life relative to forces
applied to the bearings has netted an equation (see “How Bearing Life is Affected by
Misalignment“) describing how a bearing’s life is affected by increased forces due to
misalignment.

11. As the force applied to a given bearing increases, the life expectancy
decreases by the cube of that change. For instance, if the amount of force as
a result of misalignment increases by a factor of 3, the life expectancy of the
machine’s bearings decreases by a factor of 27.
Quite a bit of research in shaft alignment has been conducted over the past
20 years. The results have led to a much different method of evaluating the
quality of a shaft alignment and to increasingly accurate methods of
correcting misaligned conditions. Based on the research and actual industrial
machine evaluations, shaft alignment tolerances are now more commonly
based on shaft rpm rather than shaft diameter or coupling manufacturers’
specifications. There are presently no specific tolerance standards published
by ISO or ANSI, but typical tolerances for alignment are shown in the table
“Typical Tolerances for Alignment.“

12. Another common method of determining shaft alignment tolerances is to
ensure the machine feet are within a specified distance from what is
considered “zero”. This method also can be misleading. If a machine is
considered to be aligned when the foot corrections are less than 2 mils at
both the front feet and back feet, serious misalignment can sometimes be
present. As a general rule, the smaller the machine footprint (distance from
front feet to back feet), the worse the alignment condition based on these
criteria for alignment tolerance.
In Fig. 1, the motor foot distance front to back is 10 inches. The distance
from the front feet to the center of the coupling is 8 inches. If the front foot
of the motor is left 2 mils high and the back feet are left 2 mils low, the shaft
alignment results will be as follows: vertical angularity of 0.4 mil/1 in. open at
the top of the coupling, and a vertical offset of 5.2 mils high at the plane of
power transmission. If this machine operates at 1800 rpm, it would be
outside the acceptable shaft alignment tolerances. Again, this reinforces that
a set of shaft alignment tolerances based on shaft rpm would apply to all
machines regardless of their footprint. MT

13. 1 -Rigid Couplings :
It is a metal to metal contact (%100 collinear)
2 -Flexible Couplings
* Spacer with shims
* Gear
* Grid
* Rubber
* Others
* Torque converter
Types Of Couplings

14. It is important because misalignment can introduce a high
level of vibration, cause bearings to run hot, and result in
frequent repairs of bearings, seals, and couplings.
Proper alignment reduces power consumption and noise level,
and helps to achieve the design life of bearings, seals, and
couplings.
DriverEquipment
Misalignment

15. DriverEquipment
Alignment

16. DriverEquipment
Vertical View
Types Of Misalignment
DriverEquipment

17. DriverEquipment
Horizontal View
Types Of Misalignment
DriverEquipment

18. Equipment Coupling
Vertically And Horizontally
Alignment Procedures
Motor

19. Motor
Coupling
Equipment
It is collinear of two center lines

20. Centrifugal pumps
2 millimeters Shims at
least

21. Pump Grouting
Special grouting concrete

22. Motor
Coupling
pump
Centrifugal pumps
80 mils Shims at least

23. 1 -Rigid Couplings
DriverEquipment
2 –Flexible Couplings
Driver
*Spacer with shims
Equipment

24. *Spacer with shims

25. *Spacer with shims
Equipment Driver
Spacer is not connected directly to both hubs,
but through the shims

26. *Gear
Equipment Driver

27. Equipment
*Grid
Driver

28. Turbine
Stationary
Guide wheel
Primary
Shaft
Secondary
Shaft
Packing
Torque
converter
Liquid
Pump
Impeller
Cooling water

29. HYDRAULIC
ENERGY
HYDRAULIC
ENERGY
Pump Turbine
HYDRAULIC
ENERGY
HYDRAULIC
ENERGY
MOTIONMOTION

30. Normal speed
Normal
Guide Blades
Higher speed Lower speed
Diversion
Guide Blades
Conversion
Guide Blades

31. Guide
Vanes

32. CommentsN/AOK
Confirm that alignment procedures, dimensional
offsets and tolerances are dictated by
manufacturer and adhered to the standard
11
Confirm the foundation grouting& anchor bolts
are prepared correctly for specific equipment.
2
3
Confirm soft foot under driver checked &
corrected.
Confirm coupling gap checked prior to final
alignment
4
5
Shaft & Coupling Run outs Complete. (refer to
vendor manual for acceptable limits):
Motor shaft run out →
Pump shaft run out →
Pump coupling hub run out →
Pump coupling hub face run out →
Description
Alignment Preparation check list

33. Confirm the vendor thermal growth correctly for
specific equipment (in case of hot fluid pumping)
6
9 Determine Magnetic centre.
Confirm proper tight for the dial indicator holder
and holding rods
10
Determine mechanical centre8
Confirm the dial indicator is rotated from the top
position to the bottom position during the
alignment procedure.
11
Confirm the proper dial indicators position
during the reversal alignment procedure .
12
Determine the thermal growth if it is not
allowable in the vendor document
7
CommentsN/AOKDescription

34. Parallel misalignment
Equipment
Vertical
OR
Horizontal
Driver

35. Angular Misalignment
Equipment
Vertical
OR
Horizontal
Driver

36. A- Parallel Misalignment
Equipment
Shims
Correcting of Misalignment
I- Vertical Plane

37. B- Angular Misalignment
Equipment
Shims
I- Vertical Plane

38. 38
II- HORIZONTAL Plane
A- Parallel Misalignment

39. 39
31
2 4
II- HORIZONTAL Plane
A- Parallel Misalignment

40. 40
31
2 4
B- Angular Misalignment
II- HORIZONTAL Plane

41. 41
Gauge Pointer
does not move around the rim
Motor and Equipment shaft
Rotate in the same time
How To Do Alignment
Equipment Driver

42. 10-10
-20
30
40
-50
20
-30
40
50
60
70
80
90
100
-60
-70
-80
-90
Flange
Dial indicator Vertically

43. 10-10
-20
30
40
-50
20
-30
40
50
Dial indicators Types and Functions
1- Balanced Type
60
70
80
90
100
-60
-70
-80
-90
Flange
Horizontally

44. 2 - Continuous Type
10
30
20
40
50
Small needle
60
70
80
90100110
120
130
140
150
160
170
180
190
Flange

45. 1- Balanced-Type
10-10
-20
30
40
-50
20
-30
40
50
Negative direction
Stem moves out
positive direction
Stem moves in
Dial indicators Types and Functions

46. • 2 - Continuous Type
10
30
20
40
50
Small needle
60
70
80
90100110
120
130
140
150
160
170
180
190

47. Preparation on Alignment
1. Before placing a machine on its base, make sure that both
the base and the bottom of the machine are clean, rust free,
and do not have any burrs. Use a wire brush or file on these
areas if necessary.
2. Common practice is to position, level, and secure the
driven unit at the required elevation prior to adjusting the
driver to align with it. Set the driven unit's shaft centerline
slightly higher than the driver.
3. Check the motor supports shims (2mm)under legs.
The following preparatory steps should be taken before
attempting to align a machine train:

48. 4. Use only clean shims that have not been "kinked"
or that have burrs.
5. Make sure the shaft does not have run out.
6. Before starting the alignment procedure, check for
"soft-foot" and correct the condition.
7. Always use the correct tightening sequence
procedure on the hold-down nuts.
8. Determine the amount of indicator sag before
starting the alignment procedure.
Preparation on Alignment

49. 9. Position the stem of the dial indicator so that it is
perpendicular to the surface and half travels..
10. Avoid lifting the prime mover more than is
absolutely necessary to add or remove shims.
11. Jacking bolt assemblies should be welded onto
the bases of all large the prime mover. add them
before starting the alignment procedure.
12. Use jacking bolts to adjust for horizontal offset
and angular misalignment and to hold the prime
mover in place while shimming
Preparation on Alignment

50. Measure and correct
* Magnetic centre
*Mechanical centre
* Thermal growth
* Run out
* Soft foot
* Pipe strain

51. EQUIPMENT
PLANT LINE
* Pipe strain
X
PLANT LINE
Maximum 0.002 in

52. * Soft foot One driver leg is not
settled on the base
Maximum 0.002 “

53. • Soft-foot is the condition when all four of a machine's
feet do not support the weight of the machine.
• It is important to determine if this condition is present
prior to performing shaft alignment on a piece of
machinery.
• As an example, consider a chair with one short leg. The
chair will never be stable unless the other three legs are
shortened or the short leg is shimmed.
• In this example, the level floor is the "plane" and the
bottom tips of the legs are the "points" of the plane.
• Three of the four chair tips will always rest on the floor.
Correcting for Soft-foot

54. Consequences
Placing a piece of machinery in service with
uncorrected soft-foot may result in the following:
• Dial-indicator readings taken as part of the alignment
procedure can be different each time the hold-down nuts are
tightened, loosened, and retightened. This can be extremely
frustrating because each attempted correction can cause a
soft-foot condition in another location.
• The nuts securing the feet to the base may loosen, resulting
in either machine looseness and/or misalignment. Either of
these conditions can cause vibration.

55. • If the nuts do not loosen, metal fatigue may occur at the
source of Soft-foot. Cracks can develop in the support
base/frame and, in extreme cases, the soft-foot may actually
break off.
• Initial Soft-foot Correction the following steps should be
taken to check for and correct soft-foot.
• Before setting the machine in place, remove all dirt, rust,
and burrs from the bottom of the machine's feet, the shims to
be used for leveling, and the base at the areas where the
machine's feet will rest.
• Set the machine in place, but do not tighten the hold-
down nuts.

56. • The following procedure describes the final soft-foot
correction:
• Tighten all hold-down nuts on both the stationary machine
and the machine to be shimmed
• Secure a dial indicator holder to the base of the stationary
machine. The stem of the dial indicator should be in a vertical
position above the foot to be checked. A magnetic-base
indicator holder is most suitable for this purpose.
• Set the dial indicator to zero.
• Completely loosen the hold-down nut on the foot to be
checked. Watch the dial indicator closely for foot movement
during the loosening process.
• If the foot rises from the base when the hold-down nut is
loosened, place beneath the foot an amount of shim stock
equal to the amount of deflection shown on the dial indicator.
Final Soft-foot Correction

57. • Retighten the hold-down nut and repeat the entire process
once again to ensure that no movement occurs.
• Move the dial indicator and holder to the next foot to be
checked and repeat the process. Note: The nuts on all of the
other feet must remain securely tightened when a foot is
being checked for a soft-foot condition.
• Repeat the above process on all of the feet.
• Make a three-point check on each foot by placing a feeler
gauge under each of the three exposed sides of the foot.
• Tightening Hold-Down Nuts Once the soft-foot is removed,
Always tighten the nuts as though the final adjustment has
been made, even if the first set of readings has not been
taken

58. The following procedure should be followed:
After eliminating soft-foot, loosen all hold-down nuts.
• Number each machine foot in the sequence in which the
hold-down nuts will be tightened during the alignment
procedure. The numbers (1, 2, 3, and 4) should be
permanently marked on, or near, the feet.
• It is considered a good idea to tighten the nuts in an X
pattern
" Always tighten the nuts in the sequence in which the
positions are numbered (1, 2, 3, and 4).
• Use a torque wrench to tighten all nuts with the same
amount of torque.

59. • Indicator sag is the term used to describe the bending of
the mounting hardware as the dial indicator is rotated
from the top position to the bottom position during the
alignment procedure.
• Bending can cause significant errors in the indicator
readings that are used to determine vertical
misalignment, especially in rim-and-face.
• The degree to which the mounting hardware bends
depends on the length and material strength of the
hardware.
• To ensure that correct readings are obtained with the
alignment apparatus, it is necessary to determine the
amount of indicator sag present in the equipment and to
correct the bottom or 6 o'clock readings before starting
the alignment process.
Indicator Sag

60. • Indicator sag is best determined by mounting the dial
indicator on a piece of straight pipe of the same length as
in the actual application. Zero the dial indicator at the 12
o'clock, or upright, position and then rotate 180 degrees to
the 6 o'clock position.
• The reading obtained, which will be a negative number, is
the measure of the mounting-bracket indicator sag for 180
degrees of rotation and is called the sag factor.
• All bottom or 6 o'clock readings should be corrected by
subtracting the sag factor.
• When two shafts are perfectly aligned, the mounting rod
should be parallel to the axis of rotation of the shafts.
However, the rod bends or sags by an amount usually
measured in mils (thousandths of an inch)

61. Shaft runout is a common measurement especially for condition monitoring.
Capacitive and eddy-current sensors provide useful non-contact measurement
solutions with distinct advantages and disadvantages.
According to ASME/ANSI B5.54-2005 Methods for Performance Evaluation of
Computer Numerically Controlled Machining Centers, “runout” is the total indicator
reading (TIR) of an instrument measuring against a moving surface. This is usually a
rotary motion and is measured for a full rotation. This means the runout value is a
combination of several types of error motions, form errors, and form factors:
Radial Shaft Runout
Radial runout is perpendicular to the axis of rotation.
Radial shaft runout is a measurement of radial displacement of the shaft surface as
the shaft turns. Assuming a round shaft, contributing factors to radial runout include
shaft straightness, drive/shaft alignment, bearing stiffness, and increasing runout as
the bearings wear. Balance is a runout factor that is dependent on the relationships
between speed and bearing stiffness and wear, and overall system stiffness. Radial
shaft runout is generally used to indicate wear in the drive bearings.
Axial shaft runout is a measurement of the axial displacement of the shaft as it
rotates. This measurement is taken at the center of the shaft (on the rotary axis). Off-
center measurements are called “face runout” in which the flatness and squareness of
the surface become contributing factors to the measurement – factors which are not
of interest in most applications. Axial shaft runout is primarily used for condition
monitoring of the thrust bearing.
Shaft Shape

62. By the definition above, non-round shapes always have significant runout. An
oval or hexagonal shaft which is rotating perfectly will still have significant
runout as the indicator responds to radial displacements of the shaft surface
due to the shaft shape.
This Application Note assumes that the shaft being measured is round.
Radial runout is affected by shaft straightness. If the shaft is bent, runout
measurements will be dependent on the location of the measurement along
the length of the shaft and the location and severity of the bend. If a shaft is
fixed at both ends (e.g. between the drive and a gear box) the maximum
runout will tend to be near the center. If the shaft is only fixed at the drive
end (e.g. motors driving fans or propellers) the runout will tend to be worse
at the floating end of the shaft.
An otherwise straight shaft may be mounted such that the center line of the
shaft is not parallel with the axis of rotation. In this case, runout
measurements will depend on where the measurement is taken along the
shaft.

63. Shaft runout is a common measurement especially for condition monitoring.
Capacitive and eddy-current sensors provide useful non-contact measurement
solutions with distinct advantages and disadvantages.
According to ASME/ANSI B5.54-2005 Methods for Performance Evaluation of
Computer Numerically Controlled Machining Centers, “runout” is the total
indicator reading (TIR) of an instrument measuring against a moving surface.
This is usually a rotary motion and is measured for a full rotation. This means
the runout value is a combination of several types of error motions, form
errors, and form factors:
Radial Shaft Runout

64. * Run out
Maximum 0.002 “
Flange
Total Run out

65. * Run out

66. * Run out
Maximum 0.002 “
Shaft

67. * Run out
Maximum 0.002 “
Flange

68. Growth factors (Expansion factor) (mil/in./F)
for common materials are as follows:
• For vertical growth, L is usually taken as the vertical
height from the bottom of the foot where shims
touch the machine to the shaft centerline.
• In the case where the machine is mounted on a base
that has significant temperature variations along its
length, L is the vertical distance from the concrete or
other constant temperature base line to the shaft
centerline.
Aluminum 0.0126
Bronze 0.0100
Cast iron, gray 0.0059
Stainless steel 0.0074
Mild steel, ductile iron 0.0063

69. * Thermal growth for hot liquid pumps
X = Shaft Thermal growth
Driver
1- Apply the alignment procedure for the pump at ambient Temp.
2- Heat up the pump by opening the start up bypass for ½ hrs.
3- Put the dial indicator on the shaft and adjust to zero reading
4- close the bypass
5- Take the dial indicator reading after 24 hrs.
6- This reading is the shaft thermal growth thermal growth
7- Add the center line thermal growth reading under the driver legs
Equipment

70. Equipment
1- Apply the alignment procedure for the compressor at ambient Temp.
2- Go to catalogue and read the center line thermal growth amount.
3- Add the center line thermal growth reading under the driver legs
4- If the equipment manual gives the whole equipment thermal growth
The center line thermal growth = whole equipment thermal growth /2
(Ask the vendor to confirm type of catalogue thermal growth )
* Thermal growth for Compressors
X = The center line Thermal growth
Driver
After minutes
of Starting

71. 71
Equipment
This design is to avoid
any thermal growth
As thermal expansion
will be in all directions
Cooling
water

72. Angular Reading
72
0
X
12 Ock
6 Ock
Vertical
Rim and Face
Alignment

73. 73
X
3 Ock
9 Ock
0
Horizontal
Angular Reading

74. Equipment
Driver
Electrical motors have no thrust bearings
Rim
Face
Radial
Bearing
Face reading is affected
by driver end play

75. Rim and Face
• The face reading error is not sensible during
rotating the motor rotor 180 deg. to measure
the misalignment reading.
• We don't know the rotor travel distance, is
inward or outward ???
• Reversal alignment has Zero error and is the
basic of the optical alignment

76. Driver
76Magnetic centre
When motor starts
The magnetic field
will fix the rotor in
the Magnetic .C.
Question :
Why Electrical motors have no thrust bearings
Answer:
They have instead a magnetic center
Pointer

77. Motor
Equipment
X
Y
D 2
Rim and Face
P
A

78. Rim and Face Alignment
is prohibited all over the world because of
the rotor axial movement affects the dial
indicator face reading
Use only
--Reversal Alignment or
--Optical Alignment

79. SAG
The attachment that will be used
Bar Sag on 12 O'clock Position
Measurement of bar sag.
Steel block
Dial indicator
Piece of Pipe

80. SAG
SAG
Sag factor
Piece of Pipe

81. 81
Gauge Pointer
does not move around the rim
Motor and Equipment shaft
Rotate in the same time
How To Do Alignment
Equipment Driver

82. Equipment
The same
Misalignment
Driver
Driver
Equipment

83. VERTICAL READINGS
Parallel actual
misalignment
Parallel reading 2xDial indicator
x

84. Parallel actual
misalignment
HORIZONTAL READINGS
2x
xIf :
- Both shafts rotate
Or - One shaft rotates,
The dial indicator
reading is the same,
And equal to:
Double of the actual
Misalignment amount

85. D1
D2
D3
MF
F
M
Reversal Alignment

86. D2
D3
D1
1-Reversal Alignment
F
M
Inboard Out board
DriverEquipment

87. F
M

88. 1-Reversal Alignment
Inboard Out board
DriverEquipment
F0
M0
Fixed
M
F 0 = Zero Reading M 0 = Zero Reading

89. 1-Reversal Alignment
Inboard Out board
DriverEquipment
F x
M x
F x = Misalignment Reading M x = Misalignment Reading
Fixed
M

90. F M
The Reversal alignment method, eliminates the
Angular misalignment due to
prime mover axial movement
Angular
Misalignment
reading

91. F M

92. Angular
Misalignment
reading
F M

93. F M

94. Parallel Reading Vertical
94
12 Ock
6 Ock
Fixed Movable
0
0
36 0
0
64
12 Ock
6 Ock

95. Parallel Reading Horizontal
12 Ock
6 Ock
Fixed Movable
0
020
0
0 40
12 Ock
6 Ock

96. 1-Reversal Alignment
Calculation Method

97. HORIZONTALLY
D 1
INBOARD + FH
{
= MH - FH
} D 2
D 1 =
D 2 =
D 3 =
Sag = ( 0 )
OUTBOARD + FV
{
= MV - FV
} D 3
D 1
OUTBOARD + FH
{
= MH - FH
} D 3
D 1 Mils
VERTICALLY
INBOARD + FV{= MV - FV } D 2
D 1
MV +32
/ 2/ 2
18FV
MH
/ 2
+20
/ 2
FH10
F M
0
0
36
20
0
0 40
64

98. Inboard
D1
D2
F
FV
98
VERTICALLY
INBOARD + FV{= MV - FV } D 2
D 1
M
MV
INBOARD = X + FV
FV
MV- FV
X
D2
D1
MV- FVX = }}
X
=
D2
D1MV- FV

99. Out board
D
1
F
FV
99
VERTICALLY
M
MV FV
MV- FV
Y
D3
OUTBOARD + FV{= MV - FV } D 3
D 1
OUTBOARD = Y + FV
D3
D1
MV- FVY = }}
Y
=
D3
D1MV- FV

100. D1 = 4 in
D2 = 8 in
D3 = 16 in
Sag = ( 0)
HORIZONTALLY
4
INBOARD + 10 = + 30{= 20 -10 } 8
OUTBOARD + 18 = + 74{= 32 - 18 } 16
4
VERTICALLY
INBOARD + 18 = + 46{= 32 -18 } 8
4
OUTBOARD {= 20 - 10 } 16
4 Mils
+ 10 = + 50
MV +32
/ 2/ 2
18FV
MH
/ 2
+20
/ 2
FH10
F M
0
0
36
20
0
0 40
64
F = 0
M = 0

101. D1 = 4 in
D2 = 8 in
D3 = 16 in
Sag = ( 1 )
HORIZONTALLY
4
INBOARD + 10 = + 30{= 20 -10 } 8
OUTBOARD + 17 = + 81{= 33 - 17 } 16
4
VERTICALLY
INBOARD + 17 = + 49{= 33 -17 } 8
4
OUTBOARD {= 20 - 10 } 16
4 Mils
+ 10 = + 50
MV +33
/ 2/ 2
17FV
MH
/ 2
+20
/ 2
FH
10
F M
0
0
34
20
0
0 40
66
F = + 1
M = -1

102. Reversal Alignment
Graphical Method

103. Vertically
Inboard
M
MV
D1
D2
D3
FFV(+)
Outboard
103
Remove shims
Add shims

104. Inboard Outboard
F M Add shims
Remove shims18 mils
16 in
32 mils
4 in
8 in
FV = 18 mils
MV = 32 mils
Vertically

105. Outboard
M
MH
D1
Inboard
D2
D3
F
FH
Horizontally
105
5/3/2006

106. EXAMPLE
16 in
8 in
Inboard
10 mils
4 in
20 mils
F M
Outboard
FH = 10 mils
MH = 20mils

107. MotorEquipment
X
Y
D 2
Rim and Face
P
A

108. Angular Reading
108
0
X
12 Ock
6 Ock
VERTICAL

109. 109
Angular Reading
X
3 Ock
9 Ock
0
Horizontal

110. Equipment
Driver
Electrical motors have no thrust bearings
Rim
Face
Radial
Bearing
Face reading is affected
by driver end play

111. Rim and Face
The face reading error is not sensible during
rotating the motor rotor 180 deg. to measure the
misalignment reading.
We don't know the rotor travel distance, is
inward or outward ???
Reversal alignment has Zero error and is the
basic of the optical alignment

112. Driver
112Magnetic centre
When motor starts
The magnetic field
will fix the rotor in
the Magnetic .C.
Question :
Why Electrical motors have no thrust bearings
Answer:
They have instead a magnetic center
Pointer

113. Rim and Face Alignment
is prohibited all over the world because of
the rotor axial movement affects the dial
indicator face reading
Use only
--Reversal Alignment or
--Optical Alignment

114. InboardX Out board
Y
P
D/2
A
P = Parallel Reading
A = Angular Reading
Rim and Face
Alignment
Equipment Driver

115. PARALELL READING
115
12 Ock
6 Ock
VERTICAL
3 Ock9 Ock.
HORIZONTAL

116. ANGULAR READING
116
0
X
12 Ock
6 Ock
VERTICAL

117. 117
ANGULAR READING
X
3 Ock
9 Ock
0
HORIZONTAL

118. OR
Inboard Out boardX
Y
Driver
D / 2
Equipment
118
PA

119. CALCULATION
METHOD
A
0
0
-16
+ 8
P
-6
0
0- 14
A = ANGULAR READINGP = PARALLEL READING

120. 120
X =
Y =
D =
Sag = - 1
-16AV
P
0
0 0
0.
A
-14
-16
+8
-6
SAG
= +1
-2
-3
/ 2
PV
AH+8-7PH
/ 2
VERTICALLY
INBOARD
X
D
AV – PV Mils=
HORIZONTALLY
INBOARD
X
D
AH – PH Mils=
OUTBOARD =
Y
D
AH – PH Mils
OUTBOARD =
D
AV – PV Mils
Y

121. X = 4 in
Y = 12 in
D = 4 in
Sag = -1
121
-16AV
P
0
0 0
0
A
-14
-16
+8
-6
SAG
= +1
-2
-3
/ 2
PV
AH+8-7PH
/ 2
12
4
OUTBOARD = { -16} – (-2) = -46
HORIZONTALLY
INBOARD { 4
4
8 } – (-7 ) = +15=
INBOARD { 4
4
-16} – (-2) = -14=
VERTICALLY
12
4
OUTBOARD = { 8 } – (-7) = + 31 Mils

122. AV = -16
D = 4
Y = 12
EXAMPLE
PV = - 2
Inboard
Outboard
PV = - 2
X = 4
PV
AV = - 16 mils
PV = - 2 mils

123. Vertically
Graphical Method
D
Y
X
AV(-)
Inboard
PV
Outboard
PV
PV
PV

124. 124
Horizontally
AH
D
Y
X
Inboard
PH
Outboard
PH
PH

125. Horizontally
AH = +8
D = 4
Y = 12
X = 4
INCHES
Outboard
Inboard
+ 7
If PH = +7

126. EXAMPLE
AH = +8
D = 4
Y = 12
X = 4
Inboard
PH =-7
Outboard
PH = - 7
PH = - 7 mils
AH = + 8 mils

127. Inboard Out board
Driver
M
Equipment
F
Optical Alignment
Transducer Reflector

128. Reflector
Shaft
BracketBracket
Chain
SIDE VIEW

129. Chain
VERTICAL
POSITION
ADJUSTTMENT
Bracket
90 PRISM
0HRIZONTAL
ANGLE
ADJUSTTMENT
Shaft

130. SCRATCH-RESISTANCE
LENS
POEWR
DATA CABLE
GREEN LED:
INDICATES BEAM
ADJUSTEMENT
RED LED:
LASER ON
WARNING
LOCKING
KNOB
HOUSING MARK
= CENTER OF
BRACKET POSTS
Transducer

131. REFLECTOR
Rotate the side thumb
Wheel to raise or lower
the reflector
This lever to lock
The reflector position
1- PRESS and remove transducer cap.
-The laser beam now is on.
-Leave the reflector cap on for now.
-Beam strikes the cap, it should be visible.
- Hold a sheet of paper to locate the beam
M

132. HORIZONTAL
ADJUSTMENT
VERTICAL
ADJUSTMENT
REFLECTOR

133. OFF Beam misses detector
Red Blinks quickly
Green Is OFF
END Beam hits non linearized
area of detector
Red & Green Blinks quickly
Alternatively
COORDINATES Beam hits area
of detector
Red & Green Blinks Slowly
Together
OFF
END
-2 1

134. 1- PREPARING FOR ALIGNMENT PROCEDURE
a- Solid flat foundation
b- Machine mobility ( 2 mm higher & screw type positioning )
c- Soft foot ( Must be checked immediately)
d- Thermal growth

135. HORIZONTAL MACHINE ALIGNMENT
Select Cycle through with andDIM
1-Transducer to reflector
2-Transducer to coupling center
3-Coupling diameter
4-RPM
5-Transducer to front feet
6- Front feet to rear feet

136. 1
2
3
4 RPM
5 6
DIM CONFIRM EACH
ENTERY WITH
ENT

137. 1-Transducer to reflector
120 mm
2-Transducer to coupling center
60 mm
DIM

138. 3- Coupling diameter D
4-Transducer to front foot, right m/c
180 mm
DIM

139. BEAM
DEFLECTOR
DIM

140. 5-Front foot to back foot , right m/c
DIM

141. Rotate the side thumb
Wheel to raise or lower
the reflector
This lever to lock
The reflector position
1- PRESS and remove transducer cap.
-The laser beam now is on.
-Leave the reflector cap on for now.
-Beam strikes the cap, it should be visible.
- Hold a sheet of paper to locate the beam
M
5-Laser beam adjustingM

142. Planned Downtime = Hours used for all planned jobs
(TPM)
Breakdown Time = Hours used for all unplanned jobs
(TBD)
Standby Time = Hours used for standby time
(TSB)
Equipment Key Performance Indicator KPI
Availability Reliability Utilization
Total Period Hours = (TX)
142

143. Reliability =
TX – ( TPM + TBD )
TX
(Re)
Utilization =
TX – ( TPM + TBD + TSB )
TX
(U t)
Av -TBD
TXTX
TX –TPM
-
TBD
TX
= =
1 -
TPM
TX
Availability =
TX – TPM
TX
(Av)
=
Re -
TSB
TX
= TX – ( TPM + TBD)
TX
TSB
TX
- =
143

144. 1 -
TPM
TX
Availability =
(Av)
Av -
TBD
TX
Reliability =
(Re)
Utilization =
(U t)
Re -
TSB
TX
144

145. EXAMPLE
Maintenance Stops For A Compressor Was As Follows:
Total Period Of 3 Months
PM = 216 HRS
BD = 216 HRS
SB = 532 HRS CALCULATE AV , Re , Ut
= 0.8Reliability =
216
2160(Re)
= 80
0
0
0.9 -
Utilization =
(U t)
0.8 -
532
2160
= 0.6 = 60
0
0
= 0.9Availability =
216
2160(Av)
= 90
0
01 -
Solution
145

146. Hassan Hassan
Isolation Standards
What types of process isolation do we have?
Single Block
Double Block and Bleed
Rated Spade or Spectacle Blind
Disconnection or Line Removal
PositiveIsolations

147. Hassan Hassan
Which valves can be used?
Not all valves can be used for isolations.
Butterfly valves, Check valves and Control Valves
cannot be considered to be part of an isolation.

148. Hassan Hassan
Which valves can be used?
Not all valves can be used for isolations.
Butterfly valves, Check valves and Control Valves
cannot be considered to be part of an isolation.

149. Hassan Hassan
Which valves can be used?
Not all valves can be used for isolations.
Butterfly valves, Check valves and Control Valves
cannot be considered to be part of an isolation.

150. Hassan Hassan
Single Valve Isolations
For Minor Work on ANSI 600 and below
Note: ANSI 600 has a Maximum Working
Pressure of 99.3 Bar
Pump

151. Hassan Hassan
Double Block and Bleed
Isolations
For Minor Work on ANSI 900 and above
Note: ANSI 900 has a Maximum Working
Pressure of 149 Bar
Pump

152. Hassan Hassan
Rated Spade or Spectacle Blind
Suitable for all isolations
Usually needs valve isolation first to allow
spade or spec blind isolation
Pump

153. Hassan Hassan
Suitable for all
isolations
Physical
Disconnection
(Line Removal)
Pump

154. Hassan Hassan
150#
1 Bar
600#
80 Bar
1 Bar
Pump Isolations
Suction may be different pressure rating than
dischargePossibility to over-pressurise suction
Sequence of isolation very important
The Correct Way Normal
Condition,
Pump Shut
Down and
Electrically
Isolated
1) Close the
Discharge Valve
2) Open the
pump vent or
drain.
3) Listen for
signs of passing
valves.
1.Close Discharge
Valve.
2. Close Suction
valve making sure
that Pump
pressure does not
rise.
3. Slowly open
drain valve and
observe pump
pressure fall to
zero.
0 Bar

155. Hassan Hassan
Pump Isolations - What can happen
Suction can be pressurised from discharge
Suction line can be damaged and personnel
can be injured
150#
1 Bar
600#
80 Bar
1 Bar
The Wrong Way
If the suction valve
is closed first, look
what happens:
1) NRVs usually
pass.
2) The Pressure
Builds up at the
pump suction.
10 Bar20 Bar30 Bar

156. Hassan Hassan
Example: Shipping Booster
What type of
isolation is
required?
Why?
How would
you do it?

157. Hassan Hassan
Example: LP Water
Pump What type of
isolation is
possible?
Is it good
enough?
How would
you do it?
NRV
NRV
BUTTERFLY
CONTROL
VALVE
BUTTERFLY