SAAS Enterprise Blg powered

We are your team members

BACK

Dial gauge and Alignment

Taking dial gauge reading for calculation of TIR (Total indication run out) is not an easy job. When it comes to practical many EXPERTS get confused. In order to understand alignment /TIR it is essential to know about dial gauge and its working.

Dial gauge A dial gauge or indicator consists of components such as bezel, indicating pointers, tool post and clamp, magnetic tool holder and sensor button. Dial indicators are available in many physical sizes and ranges. For most alignment applications the smaller sized indicators should be used to reduce indicator bar sag. Dial indicators should be chosen that have a range of 0.100 inch and accurate to 0.001 inch. Indicator readings, and many other types of readings, are expressed in several units. A reading of 1/1000" is equivalent to 0.001 inch and is commonly expressed as 1 mil.

The dial gauge have two scales. One outer scale marked (0-100) and second inner scale marked (1000).The outer scale (0-100) is to be used when dial gauge needle moves clockwise and inner scale (100-0) when dial gauge needle moves anticlockwise. When sensor of dial gauge is pushed upwards towards dial then needle on the dial moves clockwise and when sensor is moved downwards away from the dial then needle on dial gauge moves in anticlockwise direction. The dial gauge readings when needle moves clockwise are +ve where as when needle moves anticlockwise are - ve (Fig.-2). The movement of the needle should be watched for clockwise or anticlockwise rotation through out the move to avoid any confusion of +ve orve sign. All readings should be recorded as viewed from the stationary machine side to define right and left direction at the time of data entry. Backlash Error Check the indicator for backlash error. Press the sensor and then release and note down the dial gauge reading.. Repeat this process two three times. Every time dial gauge reading should be same. If readings differ then change the dial gauge. SAG calculation Dial gauges are coming with standard mounting systems. For single gauge mounting. For double gauge mounting. Some time depending on the equipment to be aligned some modification or extension is required in mounting system to carry out the alignment. If length of the tool mounting holder is more or any extension for mounting magnetic tool holder is there then there is more possibility of sagging due to weight. Mounting of the dial gauge on the bracket should be performed carefully so that dial gauge sensor axis is perpendicular to the pipe axis to ensure accuracy. Otherwise it will lead to large errors. It is essential to calculate the sag always before alignment and to be considered during calculation. For calculation of sag mount firmly the magnetic tool holder with gauge on a pipe. Adjust the dial gauge reading to zero with dial gauge sensor tip touching to pipe surface as shown in (figure-4). Now turn the pipe 180 degree and take the dial gauge reading. The difference between these two readings will give you the double of the sag value. So sag=dial reading/2

Taking the readings

After the dial gauge is firmly mounted on the shaft of the machine to be rotated then four locations at the circumference of the shaft or coupling of the stationary machine are required for taking the readings for alignment. These Four locations are at 90 degree rotation of shaft(12, 3, 6, and 9 O clock positions) as shown in Fig.-5.Please note that left right directions are marked as seen from the stationary machine side Before any readings to be taken the dial indicators must be set. Adjust the dial gauge in such a way that sensor of the dial gauge is slightly pressed against the circumference of the coupling. Rotate the machine shaft through an entire 360 degree and verify that the indicator sensor tip is in complete contact with the shaft. Now When indicator is at the top location reset the indicator to display zero. This is achieved by rotating the outer bezel of the indicator until the dial face, which is attached to the bezel, shows "0" under the needle. Collect the data by rotating the machine shaft in 90 degree increments and noting the dial indicator readings with their signs (+ or -) at Top, Right, Bottom and Left locations. If only one dial indicator setup is available, the dial gauge mounting arrangement must be relocated to the other coupling or shaft of stationary machine and the sweep should be repeated. Remember, that all readings should be collected while observing from the stationary machine to the moveable machine to maintain right and left consistency. In this case when dial gauge is mounted on stationary machine and readings are taken on machine to be moved then change the sign of readings so obtained. +ve sign to be made ve and ve sign to be made + ve. Accuracy Verification Each time the dial indicator is rotated to the top location it should display a reading of zero. If it does not then something has moved during the rotation. Correct the problem and start again. Another test, which can be performed as the data is collected, is to verify that the sum of the top and the bottom readings should equal the sum of the left and right readings. (See fig.-6). While taking dial gauge reading at the bottom portion of the shaft or coupling ,value of sag must be taken in to account. Actual dial gauge reading at the bottom of the coupling (6 o clock position) = dial gauge reading -{-(2*sag)} Assuming sag=0 Top+ Bottom reading =0+10 = +10 Right + Left reading =-12+22= +10

Calculations As the dial indicator is moved around the circumference of a coupling or shaft it displays twice the difference between the projected centerline of the indicator's attachment point and the measured shaft centerline. This is true for both the vertical and horizontal readings. This is known as TIR (Total indication run out) Thus, the sum of the vertical and sum of the horizontal readings must be divided by two to represent the actual differences in the two shaft centerlines. Remember to observe the signs of the indicator readings closely to prevent errors in these calculations. Thus actual difference in shaft centre lines (offset) in vertical plane = TIR (vertical)/2 Thus actual difference in shaft centre lines (offset) in horizontal plane= TIR (horizontal)/2 Two vertical offset numbers and two horizontal offset numbers will be obtained; one set representing the readings while the bracket is installed on the shaft of the machine to be moved and another set representing the readings while the bracket is installed on the shaft of stationary machine. Horizontal offset calculations have always remained a point of confusion. Mostly people do mistake in calculating this. This is because of the reason that one side does not start at zero. This is achieved by Adding or subtracting the value equivalent to the value of right hand side reading on both sides ( in left side reading and right side reading ) so that right side reading becomes zero. Let us take the case of Fig.-6 (All readings are in mil) Vertical TIR = 0+10=10 Horizontal right hand side reading is 12 . Horizontal left hand side reading is +22 In order to make right hand side reading zero we shall add +12 on both sides. Now horizontal right hand side reading is =-12+12=0 And horizontal left hand side reading is =+22+12=+34 Therefore horizontal TIR = 0+34=34 So offset in vertical plane is =10/2=5 And offset in horizontal plane is =34/2=17 For more details

Methods of alignment Target alignment and angular tolerance Alignment check without removing coupling

SAAS Enterprise Blg powered

We are your team members

BACK

ALIGNMENT

There are two types of alignment methods: Face and perif Reverse alignment Reverse alignment is the most accurate method, but should be used in conjunction with Face and Perif method. Face and Perif method: vertical Alignment (Angular)

Fixed machine

D1 F1

Machine to be moved F2 Fig. 1

D2 D3 F1=First hold down bolt F2=Second hold down bolt D1=Diameter of the circle made by dial indicator tip when coupling of the fixed machine is rotated 360 deg. (mm) D2=Distance from Pointer of dial indicator to first holding down bolt F1.(mm) D3=Distance from pointer of dial indicator to second holding down bolt F2. (mm) Always align angular misalignment first in both vertical and horizontal alignment. For vertical alignment, zero dial indicator at T.D.C .Rotate through 180 and note total indicator reading (T.I.R) and sign. To calculate the amount of shims required under F1 and F2, following method can be used Ratio between D1 & D2,D1 & D3 are required. Example Say: D1 = 50mm D2 = 100mm D3 = 200mm R1=100 /50=2 and R2=200/50=4

If dial indicator reading = +0.2mm Then distance between coupling faces are greater at the top than bottom Add 0.2 X 2= 0.4mm at F1 0.2X 4 =0.8mm at F2 When T.I.R = o.1 or less check for height alignment, as per the fig 2

Fixed machine

Machine to be moved Fig. 2 F1 F2

Once angular alignment has been achieved, equal amounts of shims can be removed or added as calculated below. zero dial indicator at T.D.C .Rotate through 180 and note total indicator reading (T.I.R) and sign. For a minus dial indicator reading ,add shims under m/c to be moved equal to that of the indicator reading. For a plus indicator reading remove shims under machine to be moved equal to that of the indicator reading. HORIZANTAL ALIGNMENT(ANGULAR) Three dial indicators are required. Positions are shown in fig 3

F1 Fixed machine D1

F2

Machine to be moved F1 F2 Fig. 3

D2 D3 Method Zero dial indicators (D.I) and rotate through 180.Note the reading and sign minus or plus. Using fig. 1 find ratio R1 and R2,calculate distances to move m/c at D2 and D3 . Zero dial indicators positioned at feet of m/c to be moved and move machine until indicators read calculated dimensions when T.I.R = 0.1mm or less, horizontal alignment can be checked. Positions D.I as shown in Fig 3 .Zero DI and rotate through 180.Note indicat or eading and sign. Zero D.I position at feet of m/c to be moved and mov machine until both D.I indicate error previously recorded. (2) REVERSE ALIGNMENT A D1

Fixed machine F1 B D2 P

Machine to be moved F2 Fig. 4

D3

A=clock dial indicator on coupling hub (fixed m/c) B=clock dial indicator on Coupling hub (machine to be removed) F1=First holding down bolt F2=Second holding down bolt D1=Distance between dial indicators D2=Distance from p to first holding down bolt D3=Distance from P to second holding down bolt Before starting the alignment, an alignment Graph must be made-see attached graph 1 Install clock dial indicators as in Fig 4 2 With Marker pen mark of the positions of dial indicators on the coupling hubs. METHODS FOR VERTICAL ALIGNMET Always stand with the fixed m/c on your left hand side, and m/c to be moved on your right hand side. (1) Position the dial indicators as shown in the fig 4. with the A dial on the top of the Fixed m/c coupling hub, and the B Dial indicator at the bottom of the m/c to be moved. (2) Set the indicator to zero and turn both coupling hubs through 180.Note the T.I.R of the A dial indicator and if the reading was plus or minus. (3) Set the B dial indicator to the top and turn both coupling hubs through 180.The B dial will now be back at the bottom of the hub. Note the T.I.R of the B dial indicator and if the reading was plus or minus PLOTTING READINGS ONTO GRAPH A 0.2 0.14 0.05 0,0 0.15 D1 D2 D3 Subtract shim =0.05 mm Add shim = 0.15 B F1 F2 A= + 0.4 /2 =0.2 B= 0.28/2 =0.14 Reverse sign

Example: A dial reading of +0.4 mm T.I.R B dial reading of -0.28mm T.I.R On the A line of the graph, plot half the T.I.R of the A dial indicator to pre-determined scale. As the reading was plus, the mark has to go above the pump center line. On the B line of the graph, plot half the T.I.R of the B dial indicator to the same scale ,but in this case you must reverse the sign. In the Example from minus to plus This is very Important. Plot point on graph above center line. Note:If the reading B dial was plus, reverse sign to minus. Plot point below center line of graph. Place a straight edge through the two points and draw a straight line passing through points F1 and F2.Te distance from the center line to the plotted line will be the amount of shims to be added or subtracted from F1 and F2 respectively. If the plotted line is above the center line, subtract shimsand below add shims. HORIZONTAL READINGS

A F1 Fixed machine

F2

Machine to be moved F1 B F2 Fig. 5

Horizontal readings are taken the same way as for vertical readings. Only the dial indicators are set in plan view. In the horizontal position the m/c to be moved is physically moved on the base frame, as shown in Fig 5.Placing dial indicators at the feet of the m/c to be moved, move m/c in accordance with plotted graph. Ensure that you are moving m/c in the correct direction. Make a note on the graph which way a minus or plus has to be moved in the horizontal position i.e Away or Towards you. Please note the following rules: (1) Always check that you have the correct distance between coupling ends. (2) When aligning Multistage Centrifugal pumps, fill pump casing with water push pump shaft into pump body to separate wear plate faces. This is very important as the wear plate faces can pick up if this is not done. (3) Always rotate both couplings together to eliminate coupling run out. MORE

SAAS Enterprise Blg powered

We are your team members

BACK

Relative reference displays the current body's centerline referenced to the previous body. Relative reference allows you to determine
if your alignment is within the desired coupling angular tolerance at Ambient and Operating temperatures. See example below (Fig.-2,3)

Absolute reference shows the current body's position referenced to the leftmost (fixed) body. Absolute reference allows you to check
for sufficient hold-down bolt clearance in all bodies in a train to effect an alignment without disturbing the fixed body. Useful for initial installations.

Thermal Movement is the vertical and horizontal shift in the centerline of a body due to the change in temperature from when it was
aligned to operating temperature

Target alignment is the alignment to which all the shim change and horizontal movement calculations are referenced. It is the relative
position of both bodies at the temperature at which they are being aligned, corrected for expected thermal movements. See example below ( figure-2) Fixture Sag is the measured bending of the alignment fixture due to its stiffness, weight, and gravity. Because of sag, the dial indicators will render false readings. Sag must be measured and algebraically subtracted from the dial indicator readings to determine the actual shaft relative positions.

Flexible couplings allow equipment shafts to operate with some deviation from perfect alignment by distorting the flexible elements.
This deviation usually consists of a parallel offset and an angle that can be resolved into a single angle that the flexible element sees. This resolved angle is called the Angular Tolerance. A coupling Flexible Element can be a disk pack, diaphragm, gear, spider, etc. In other words, the bit that bends, or flexes.

Angular Tolerance is the maximum angle that the flexible elements are allowed to distort during operation. This angle, when rotated
through 360 degrees, defines a cone with its apex (point) at the center of each flexible element ( Right side -Figure 1). The centerline of a shaft (or coupling spacer) that operates within this conical region is deemed to be in tolerance.

Figure 1

Flexible coupling

Since physical adjustments are in the vertical (shim changes) and horizontal (side to side), results are shown in Vertical and Horizontal plots in the Graphic Plot . The same two views of the cone appear as triangles on these plots. A centerline lying on, or near, the outer edge of both triangles may at first appear acceptable (Red lines - Left side Figure 1). In reality, the centerline will lie outside the cone when the two projections are resolved to the true position (Blue line - Right side Figure 1).

Example of Target alignment

Flexible coupling Figure-2 (centre line of all bodies during operation)

5 Take the case of a Turbine driven Compressor with Gear box as shown in the figure-2. Assumptions Ambient temperature=25 deg C

Thermal expansion = 1.2*10 per deg. C Compressor shaft height from base= 800 mm Compressor shaft brearing area temp. during operation = 70 deg C Gear box shaft height from base =450 mm Gear box shaft brearing area temp. during operation =55 deg C Calculations for shaft height increase during operation Turbine shaft height from base =700 mm Turbine brearing area temp.during operation = 55deg. C Increaseshaft in height of compressor shaft during operation = [1.2*800*(70-25)] /100000 =0.432 mm Increase in height of Gear box shaft during operation =[1.2*450*(55-25)]/ 100000 =0.162 mm Increase in height of Turbine shaft during operation =[1.2*700*(55-25)]/ 100000 =0.252 mm

Based on above calculations the Relative reference of all the three bodies at ambient temperature will be as shown below. Black dotted lines indicate the shaft centre lines of Compressor, Gear box and Turbine at ambient temperature. Green dotted line indicate the shaft centre lines of Compressor ,Gear box and Turbine under operating condition .

0.162 mm COMPRESSOR 0.27 mm

GEAR BOX 0.09

TURBINE

Figure-3 (shaft height cold alignment) 0.432-0.162 =0.27 0.252-0.162 =0.09

SAAS Enterprise Blg powered

We are your team members

Alignment Check Without removing coupling

BACK
Many maintenance departments in smaller plants still think that alignment is only needed for large, high-speed shafts. Many have no idea how to align two shafts beyond using a straight edge to get them close. The supplier who sells the couplings says that the coupling can take up to one degree of misalignment and not hurt anything. They design couplings that will not wear out with that much misalignment. It does not speak of equipment safety. Badly aligned shafts will ruin the bearings on the equipment in short time. All shafts, even low speed ones, must be aligned to within a few thousands of an inch TIR (Total Indicator Run out) if the bearings are to last for their full life.

Flexible coupling

A=Fixed machine side coupling B=Movable machine side Coupling D=diameter of the coupling L=Distance between two couplings

Fixed machine coupling

Coupling of machine to be moved

Actual Relative position of the driving Machine and the Driven machine can be checked by using the coupling as installed. It is recommended to check the machine alignment when the machines are shut down for schedule shut down. The alignment of the machines may be readily checked with a dial indicator clamped to the center of the tube. Clamp or place the indicator base on the tube. Place the indicator tip on the face of the guard near the OD. Zero the indicator at 12O clock. Rotate both machines, flexible coupling and indicator at the same time. Take reading at 3o clock,6 oclock,9 oclock and 12 oclock reading doesnt repeat zero, re zero the indicators and retake the readings. Take the second set of readings at the other end of the couplings. Record the readings on the data sheet. Calculate total indicator run out. Remember a POSITIVE reading occurs when the tip moves towards the indicators. BE CAREFUL of your SIGNS (+,-) when adding and subtracting. The flexible diaphragm coupling can accommodate misalignment by both end diaphragms angular deflection. These diaphragm couplings are classified by allowable angular deflection. For example For 200 Series flexible coupling (T.I.R)<D* tan () =0.0087* D 300 Series (T.I.R)<D* tan (1/3) =0.0058* D 400 Series (T.I.R)<D* tan () =0.0043* D Please check the name plate mark and series number mark on your flexi-unit and review the T.I.R readings taken by dial gauge against the figures above. Coupling shall not be installed or operated at misalignments greater than those figures. However, it should be noted that the checked figures are based on the static conditions, the misalignment figures may vary with temperature and other factors. If the readings are taken immediately after the machine is stopped then misalignment figures will be very near to operating conditions. Therefore, alignment should be done as precisely as possible. Where D = Diameter of the coupling flange T.I.R = Total indicator Run out

Calculation for the alignment accuracy:

Alignment Accuracy = Maximum (X,Y)/L where offset readings at A=X and at B=Y X = ( AV + AH ) Y = (BV + BH ) AV and AH = amount of offset, vertically and horizontally, at the power transmission point (coupling Flanges) on the stationary machine. BV and BH = amount of offset, vertically and horizontally, at the power transmission point (coupling Flanges) on the moveable machine. Maximum (X, Y) = larger of X or Y, calculated above. Plotting the resultant alignment accuracy on the chart will determine whether the existing alignment condition is acceptable or not. Coupling A Coupling B L

0.003 0.002 0.001 X Y

0,0 -0.001 -0.002 -0.003

SAAS Enterprise Blg powered

We are your team members

BACK

TURBINE ALIGNMENT

Home About Us Contact Us General Engineering Service Detail Related Links Response Form Membership Form Womens corner Members News Article Woman of Substance B2B

Many methods can be utilized to perform cold alignment of Turbine. The method described below is that of using dial indicators. While the method of employing dial indicators is an old and well established technique, it is not without problems. Some of them are 1.Inaccuracies in the geometry of the coupling hubs. 2.Axial float of the two shafts 3.Radial clearances of the bearings. 4.Difference between exhaust end shaft rise and steam end shaft rise 5.Sag in the brackets used for holding dial indicators. The most widely used of the traditional alignment methods is commonly referred to as the Face- O.D. method as illustrated in Figure1. As shown in the figure, a bracket is attached to one shaft and extends to the proximity of the coupling hub on the adjacent shaft. Dial indicators are affixed to this bracket with the stem of one indicator resting on the face of the coupling hub and the stem of the other indicator resting on the outside diameter of the same hub. The offset of the shafts is determined by the O.D. readings, while angularity of the shafts is determined by the face readings. It is suggested that the proper distance between the shafts be established before any alignment method is used in order to fix the coupling without disturbing the alignment. This spacing dimension can be found on the coupling drawing.

To eliminate inaccuracies in geometry of the coupling hub, turning of both shafts simultaneously such that the indicator readings are taken always at the same place on the hub will give more precision. This precaution can be difficult on larger equipment and may not be possible. Face measurements taken by this method must have the axial float of the two shafts accounted for. Axial movement must be taken into account when turning the shafts on equipment with hydrodynamic thrust bearings or no thrust bearings. (Small machinery utilizing ball bearings will not encounter any axial float.) The shafts must have axial positions rechecked each time a reading is taken. Similarly during horizontal alignment of the turbine the off set (equivalent to the radial clearance in the input bearing of the gear box installed between driven equipment and turbine) should be kept between centre line of the turbine shaft and the centre line of the gear box due to the tendency of the gear box shaft movement out side under load condition. One additional element that must be accounted for is the difference between the exhaust end shaft rise and the steam end shaft rise. Typically, the steam end will rise more than the exhaust end due to higher temperatures. This will result in the desire to have the coupling face open at the top. The calculated shaft rise for both the steam and exhaust end can be found on the outline drawing for the turbine. Care must also be taken in the brackets that are used to hold the dial indicators. Universal or makeshift brackets contrived on the spur of the moment can give inaccurate readings, which can lead to improper alignments. Especially when the spans between the shafts are quite long, care must be taken to assure that the bracket being utilized is stiff enough that it will not deflect under its own weight. A step up in accuracy and the elimination of some of the problems mentioned above with the Face O.D. would be to utilize the Reverse Indicator method as illustrated in Figure 2. This method employs indicator readings taken on the outside diameter of the coupling hubs or shaft only. The sketch indicates two brackets used simultaneously, which is normally the preferred method. One bracket could be utilized by switching back and forth for each set of readings but this is far less convenient.

Use of the Reverse Indicator method eliminates the requirement for removing the coupling spacer in a majority of cases. This reduces the wear and tear on the coupling. The error caused by coupling hub run-out is entirely eliminated since both shafts turn as a unit (with spacer installed), and angular misalignment is greatly magnified and more precisely diagnosed. Since face readings are eliminated, there is no concern about axial float. The single problem that carries over to the Reverse Indicator method which was present in the Face O.D. method is that of deflection in the alignment bracket. This problem can be readily handled by building the bracket with substantial material to prevent droop or by determining the deflection in the alignment fixture and making the appropriate corrections in the alignment data. For the purpose of example, Figure 3 shows a simple turbine-compressor to be aligned. It is desired to place the compressor shaft .008 higher than the turbine to accommodate for calculated thermal growth of the two machines. The alignment bracket is clamped to the turbine shaft with the indicator stem resting upon the compressor shaft (or

the rigid portion of the coupling hub).

The indicator is zeroed on top and the following readings are observed as the shafts are rotated at 90-degree intervals. A similar procedure is used with the complementary bracket and the indicator yields to following:

This data obtained is adequate to determine relative shaft positions. Record the readings and indicate precisely what they represent. As they are shown above, the readings shown as Turbine to Compressor indicates the alignment bracket is on the turbine shaft and the indicator stem rests upon the compressor shaft. Make any corrections for the deflection of the alignment bracket. For this example, we will assume .004 TIR deflection. To make the correction for this error, simply add the TIR reading (in mils) to the bottom number in each set.

Turbine to Compressor and Compressor to Turbine For ease of plotting, change each pair of numbers to zero and a positive number. Since diametrically opposed numbers represent only a deviation from an arbitrary reference, a given amount may be added to both sides without affecting the meaning. On the Turbine to Compressor readings, for example, 10 is added to the vertical pair of numbers while 8 is added to the horizontal pair. The other sets are handled in a similar manner. The absence of negative numbers reduces errors in plotting.

In Figure 4, the points shown above have been plotted on a scaled sketch of the turbo machinery train. Any convenient scale may be used. In this example, it is assumed the turbine will remain stationary and the compressor will be shimmed to achieve the desired alignment. From the Turbine to Compressor data, it can be seen that the centerline of the compressor shaft is .005 (one half of the TIR reading) above the centerline of the turbine shaft for the point at which the indicator readings were taken. Now referring to the Compressor to Turbine data, it can be seen the centerline of the turbine shaft is .012 below the centerline of the compressor shaft for the point at which the indicator readings were taken. With these two points determined, the position of the compressor shaft relative to the turbine shaft is fixed. An extension of a line through these two points gives a graphical representation of the alignment situation and indicates the shimming necessary to achieve the desired alignment. It is also at this point in the alignment procedure that the offset required due to the steam end rise be greater than the exhaust end rise must also be taken into consideration. In this example, the vertical plane has been plotted. Alignment in the horizontal plane is obtained in the same manner. On next page more