Basic knowledge and Method osf shaft alignment

1. Shaft Alignment
Prepared By
Muhammad Nadeem (EMT)

2. Contents
•Introduction/Definition
•What are the symptoms of misalignment
•Pre Alignment Checks
•Types of Alignment
•Alignment Method
•Effects of Misalignment.

3. Introduction/Definition
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).

4. What are the symptoms of misalignment
 Premature bearing, seal, shaft, or coupling failures.
 Excessive radial and axial vibration.
 High casing temperatures at or near the bearings.
 Excessive amount of oil leakage at the bearing seals.
 Loose foundation bolts or broken coupling bolts.
 The shafts are breaking (or cracking) at or close to the inboard bearings or
coupling hubs.

5. Pre Alignment Checks Soft Foot
 This condition occurs most frequently well known as
table leg condition. Soft foot causes frame distortion.
 Two methods are commonly used for soft foot correction
 Tighten all hold down bolts then loosen one bolt at a
time and note the deflection
 Soft Foot checks
 Dial Gage
 Feeler Gage

6. Pre Alignment Checks Bracket sag
The Inclination towards downwards in alignment Bracket due to gravitational
force is called Bracket Sag.
 Corrected Indicator Readings
 True Indicator Readings = Measured Readings – Sag Readings
TURBOLINK
0.05 mm
TURBOLINK
0.05 mm

7. Pre Alignment Checks Run out
 Shaft & Coupling
TURBOLINK
TURBOLINK

8. Types of Alignments
 Before we start learning about the procedure for alignment it is very
important that we first know the types of misalignments. Generally
there are two main types of misalignments
 Parallel (also known as offset)
 Angular (also known as gap)
 In parallel or Offset misalignment, the two shafts to be aligned have
centerlines that are parallel to each other but are in offset
condition.

9. Angular Misalignment
 angular misalignment the axis of the two shafts are located at an angle to
each other.
 angular misalignment can be further subcategorized as either horizontal or
vertical misalignment. Angular horizontal misalignment occurs when the
motor shaft is at an angle with the pump shaft, but both shafts still operate in
the same horizontal plane. Angular vertical misalignment occurs when the
motor shaft is at an angle with the pump shaft, but both shafts still operate in
the same vertical plane

10. Alignment Methods & Resolution
Laser

11. The feeler gauge and straight edge method
 This is the easiest method of alignment, but it is also the least accurate, and is
not recommended for high RPM machinery. It's only recommended for machines
fitted with flexible couplings capable of tolerating up to 1.5° angular run-out
and 0.25mm parallel run-out.

12. Alignment Methods Using Indicator
Rim & Face Shaft Alignment
Reverse Shaft Alignment
Applications
Rim & Face Shaft Alignment
Trains where one shaft can’t be rotated during the alignment process.
Machines with coupling hubs that are axially close to each other.
Machines that have large diameter couplings.
Small general purpose machines
Reverse Shaft Alignment
Long span machines
Machines that require precision alignment.

13. Correct & Collect Readings & Calculation in Rim & Face.
 Since any alignment readings taken by this method will include not only
misalignment but also bracket sag, sag must be removed from the reading to
yield only misalignment .Calculation shims for Angular Alignment using the
formula given below:“
 C”Shims Required = Angular Displacement X C / A
 B”Shims Required = Angular Displacement X B / A
 Calculation shims for Parallel Alignment using the formula given below
 Shims Required = Parallel Displacement/2

14. Reverse Shaft Alignment Graphic Method

15. Graphical Solution

16. By Formula for Shim calculation in
Reverse dial

17. By Formula for Shim calculation in Reverse dial

18. By Formula for Shim calculation in Reverse dial

19. Laser Alignment
 Laser shaft alignment is the most efficient way of aligning machine shafts. Put
simply, it saves time and money:
increased machine availability, prolonged service life and maintenance intervals,
lower power consumption!
 Easy to Use Even for Beginners
 Quick and Easy Set-Up of Fixtures
 Measure with a Smaller Shaft Rotation
 Consistent Results and Easily Recordable Data
 Error free and accurate measurement: No human uncertainties, no bracket sag
influence and no reading errors
 Straightforward alignment procedure: System can be used by any operator
 Quick on-screen laser beam adjustment Universal precision brackets designed for
quick and rigid set-up
 Automatic computation of horizontal and vertical coupling and foot values
 Clear graphical representation of the machines with the corresponding foot
correction value
and direction “Live move” shows updated values and the direction of the correction.
Reports generated directly from instrument, in conformity with ISO 9001
documentation requirements
 Powerful Software

20. Laser Alignment Tool Parts

21. Effects of Misalignment
 Excessive Vibration – Misalignment is one of the leading causes of equipment vibration.
In spite of self-aligning bearings and flexible couplings,
 Noise – Like vibration, noise can be detected simply by noticing a change in the
equipment sounds during operation. All running equipment produces a certain normal
amount of noise. Only if an operator is familiar with normal equipment noise will they
be able to detect abnormal sounds.
 Lost Production – Misalignment can directly affect the lifetime of equipment. With a
shortened service life, equipment will require unplanned maintenance, thereby
reducing the time available for production.
 Poor Quality of Products – Product quality can suffer directly from equipment
misalignment. Misalignment can cause both the manufacturing process to produce
defects and directly damage product.
 Higher than Normal Repair Orders – Misalignment-induced failures will increase the
amount of unplanned maintenance, causing more repair orders to be generated.
 Increased Inventory of Spare Parts - As the amount of maintenance increases due to
misalignment-induced failures, more spare parts will need to be ordered. This results in
increased spending and a larger spare parts inventory.
 Reduced Profits – As machines fail early and unexpectedly, more money must be spent
for maintenance and spare parts. Coupled with lower production, misalignments can
rapidly reduce profitability.

22. THANKS
Thank you so much for your
patience & kind attention !!!