This Presentation shows different types of Machine & Axle Alignments. It also shows What all types of Mis Alignments

1. MACHINE ALIGNMENT

2. ALIGNMENT
Alignment is the process of keeping the Axes of the
Driver and The Driven Shafts in ONE STRAIGHT LINE.

3. MISALIGNMENT Parallel
When the Shaft Axes are not in one line but are
Parallel, it is termed as Parallel or Radial
Misalignment.

4. MISALIGNMENT Angular
When the Shaft Axes are not in one line but intersect
at an Angle, it is termed as Angular Misalignment.

5. MISALIGNMENT
Parallel & angular combined
When the Shaft Axes are not in one line but are
Parallel and intersect at an Angle, it is termed as
Combined Misalignment.

6. MISALIGNMENT
Misalignment may be :-
• PARALLEL
• ANGULAR
• COMBINED PARALLEL & ANGULAR.

8. COUPLING MOUNTING

9. MISALIGNMENT.
While Aligning, Care and Adjustments are
taken for :
•END FLOAT.
•TORTIONAL FLEXIBILITY.

10. CHECKS BEFORE STARTING
ALIGNMENT.
• Coupling gap.
• Soft foot.
• Indicator sag.
• Dial indicator rigidity.
• Alignment readings. (0°, 90°, 180°& 270°)
• Thermal growth. (Steel-0.01mm/m for
1°C rise in temperature.)

11. ALIGNMENT : Coupling Gap
The shaft gap should be in accordance with
the coupling manufacturer’s
recommendation.
Some equipment like Motors have an
inherent freedom to float . It should be at the
Motor’s magnetic center.

12. ALIGNMENT : SOFT FOOT
SOFT FOOT is the condition, when all
feet of the Pump or Motor are not in one
plane.

13. ALIGNMENT :
How to Detect SOFT FOOT ?
• Put Machine on base.
• Do not tighten bolts.
• Attempt to pass thin Feeler
Gauge Blade under a Foot.
• If the blade passes, that foot has Soft
Foot.
• Check other feet.

14. ALIGNMENT :
How to Rectify SOFT FOOT ?
• Measure Soft foot gap.
• Tighten all hold nuts
• Put Dial Gauge on each foot & loosen the Bolt.
• If foot rises, put Shims.
• Repeat process for each foot.
• Always tighten bolts in one sequence.

15. Indicator Sag
Determine the difference between the dial indicator reading when it
is on top of a shaft as opposed to when it is at the bottom.
This is a gravitational effect. It will always be on the negative side.
It is to be corrected in top – bottom readings but has no influence
on the horizontal readings.
Dial Indicator Rigidity
The dial indicators as well as the clamps should be
fitted as rigid as possible to eliminate sliding and
resultant erroneous readings.

16. Alignment Readings
The dial should be zeroed at the top for convenience. The
coupling bule should be marked at 0°, 90°, 180°& 270°
with a reference mark on the equipment such that nuts can
be turned by 90° increments. Both the equipment are to be
rotated simultaneously in order to eliminate run out.
After rotating all four positions make sure that the indicator
returns to zero.If not, discard the reading and repeat the
procedure.

17. Thermal Growth
If a pump is pumping hot water it will grow due to
thermal expansion from cold static condition to the
hot running condition. The objective is to operate
the machinery in properly aligned when working
under normal operating condition. Compensation
for these predicted thermal movements can be
made by providing some preset offset in the cold
static condition.

18. ALIGNMENT AND COUPLING AND ITS EFFECT
ON VIBRATION
At the beginning of most predictive maintenance programmes,
misalignment of direct-coupled machines is by far the most
common cause of machinery vibration.
In spite of self-aligning bearings and flexible couplings it is difficult
to align two shafts and their bearings so that no forces exist which
will create vibration.
Hence the most widespread mechanical problem in the industry
today is misalignment.
Although vibration responds to the degree of misalignment there is
not a direct 1-1 relationship between the amount of misalignment
and amount of vibration.

19. Component Failure due to misalignment:
It can cause failure of not only coupling but also
bearings and other moving parts of the system
itself.
Direction of Potentially harmful forces:
It is possible that the highest reaction is on the free
outboard end instead of coupling end due to
increased stiffening.

20. Axial Vibration: Misalignment normally causes both axial and
radial vibration as opposed to unbalance (except overhung
rotors).
Other sources of High Axial Vibration:
Bent shafts, Shaft in resonant whirl, Resonance of same
component in axial direction, Worn thrust bearings, Worn
helical and Bevel gears, a sleeve bearing motor hunting for its
magnetic center, Couple component of dynamic unbalance.
Whenever high axial vibration occurs, one should not make a
conclusion that the problem is misalignment.

21. CHARACTERISTICS OF MISALIGNMENT
2X RPM Vibration: Often misalignment generates a higher
than normal 2X RPM vibration which can act not only in
the axial direction but also in radial direction. The second
operating speed harmonic is caused by asymmetric
stiffness in the machine and its supports or in coupling.
There is often quite a difference in stiffness around the
supporting housing frame, foundation and coupling itself
allowing the back and forth motion in each revolution
thereby resulting in 2X RPM vibration.
Multiple Harmonics: They appear when vibration is more
severe. The key distinguishing feature is still the high level
of 2X RPM.

22. Phase is the best indicator: Phase behavior in response to
misalignment is as given below:
Probably the best indicator of misalignment problems is the evaluation of
phase across the coupling. When the phase difference across the
coupling approaches 180° ( 40° - 50°) misalignment is indicated. The
more severe the misalignment the more thus difference will approach
180°.
Since it is possible for shafts to have better horizontal alignment ,
horizontal phase difference may be different from vertical phase difference
across the coupling.
While examining the phase difference on one of the rotors (just the motor
or fan) the radial phase difference for significant misalignment will be 0° or
180° ( 30°).
When comparing horizontal phase difference with vertical phase
differences on the same rotor about 90% of misaligned machines will
show a difference approaching 180°.

23. Angular Misalignment:
1. It primarily generates high axial vibration particularly at 1X and 2X RPM.
2. Typically when the amplitude of either 2X RPM or 3X RPM exceeds approximately
30% to 50% of that at #X RPM in the axial direction angular misalignment is
indicated.
3. Angular misalignment is best detected by 180° phase change across the coupling
in axial direction.
Parallel Misalignment:
1. It affects radial vibration as opposed to angular which effects axial vibration.
2. It causes phase differences to approach 180° in the horizontal direction.
3. 2X RPM exceeds 50% of 1X RPM.
Misaligned Bearings Cocked on Shaft:
1. A cocked bearing will normally generate considerable axial vibration which affects
1X RPM & 2X RPM.
2. If phase is measured in the axial direction at each of a 4 points 90° apart from each
other, a cocked bearing will be indicated by 180° phase shift from top to bottom
and side to side.

24. COUPLING PROBLEMS:
Proper interpretation of vibration data provided by the new generation
equipment can help to pinpoint some of the coupling problems.
2X RPM will often respond to coupling problems particular a coupling
having a spacer too short or too long.
In these cases both the radial and axial direction will show a fairly
noticeable 3X RPM component.
Gear type couplings can experience coupling lock up where the frictional
force developed at gear teeth is greater than the applied force causing
the coupling to become a rigid member. Friction welding of teeth.

25. ALIGNMENT TOLERANCES :
MACHINE RPM TOLERANCE (mm)
<1000 0.08 to 0.11
1000 – 2000 0.05 to 0.10
2000 – 4000 0.025 to 0.05
4000 - 6000 0.013 to 0.025

26. METHODS OF ALIGNMENT :
• Straight Edge, Feeler Gauge & Level.
• Reverse Indicator Alignment
(graphic)
• Face & Rim Alignment. (graphic)
• Across Flex element. (graphic)
• Mathematical Method.
• Laser Beam Method.

27. ALIGNMENT :
can be done in Two stages -
1. PRELIMINARY ALIGNMENT.
2. ACCURATE ALIGNMENT.

28. Done with the help of
• Straight Edge
• Feeler Gauge.
PRELIMINARY ALIGNMENT :

29. PRELIMINARY ALIGNMENT :
Straight Edge -

30. PRELIMINARY ALIGNMENT: Feeler Gauge

31. ACCURATE ALIGNMENT
with the help of
DIAL GAUGE

32. ACCURATE ALIGNMENT :Dial Gauge

33. ACCURATE ALIGNMENT :
Dial Gauge

36. Alignment calculations
a) Distance corrections = 700 / 200 = 3.5
3.5 x 0.25 = 0.875 mm shim is to be given under
each back foot.
b) Corrections when front feet are to be raised :-
Distance corrections = 400 / 200 = 2.0
0.25 x 2 = 0.5 mm shim is to be given under each
front foot.

38. TOP

39. FAR

40. BOTTOM

41. NEAR

42. Reverse Indicator Method

43. Reverse Indicator Method
Reading on pump.
0.00
- 0.025
- 0.015
- 0.005
Motor
Pump

44. Pump
Motor
Reverse Indicator Method
Reading on motor.
0.00
+ 0.005
+ 0.004
+ 0.006

45. Calculations :
Pump Motor
Vertical.
- 0.025
- 0.000
- 0.025
Sag (-)-0.005 (+)
- 0.020 / 2 =
Vertical.
+ 0.005
- 0.000
+ 0.005
Sag (-)- 0.005 (+)
+ 0.010/2 =
Horizontal.
- 0.005
(-) - 0.015 (+)
+0.010 /2 =
Horizontal.
+ 0.006
(-) +0.004 (-)
+0.002 /2 =
- 0.010 + 0.005
+ 0.005 + 0.001

46. Calculations :
Vertical Horizontal.
Pump Motor Pump Motor
Reading - 0.010 + 0.005 + 0.005 + 0.001
Position on
graph.
Bottom Bottom Top Bottom

47. Pump to motor alignment guide.
Vertical (Side view) Horizontal (Top view)
Reading on pump Reading on motor Reading on pump Reading on motor
+ on bottom + on bottom + Near side + Near side
- on bottom - on bottom - Near side - Near side
+ on bottom - on bottom + Near side - Near side
- on bottom + on bottom - Near side + Near side
Pump shaft Motor shaft

48. P M FF BF
0.01
P M FF BF
0.007
0.019
Vertical correction
Horizontal correction

49. Conclusion :
Top – Bottom correction :
• The motor shaft : Only the back feet
have to be lowered by 0.01”
Far – Near correction :
• The motor shaft has to be shifted
towards far end so that the front feet is
pushed by 0.007” and the back feet by
0.019”

50. Multi Unit Alignment

53. FACE AND RIM METHOD

57. Across the flex element.

62. Mathematical Method.

65. LASER BEAM METHOD