LESSON

FACTOR AFFECTING THE ALIGNMENT

LECTURE
SUB-OBJECTIVE
At the end of this lesson the trainee will be able to demonstrate an understanding
the factor affecting on alignment.

1.0

INTRODUCTION
Many types of plant equipment including pump fans belt drives, gear boxes
electric motors, turbines and even generators are the driven equipment or
prime over. The driven and prime over equipment must connected to each
other by some device (coupling) with correct alignment.
Correct alignment is defined as a perfectly straight line running through the
center line of the two shaft and that the faces of the two half couplings are
exactly at right angle to this line.

2.0

VALUE OF PROPER ALIGNMENT

Why is correct alignment so important to equipment operation? The
condition of misalignment of shafts causes the majority of machine
component failures. This is due primarily to accepting tolerances that should
not be accepted and also accepting apparently good readings which, in
reality, are false.
Misalignment, regardless of the magnitude will result, eventually in unnecessary mechanical problems which will require time and money to
correct. The most affected parts of a unit that suffers from misalignment are:
1.
2.
3.

2.1

Coupling
Bearing & Seals
Shaft

EFFECT ON COUPLING
The most affected part of a unit that suffers from misalignment is the
coupling. Regardless of the type employed on a unit, either rigid or flexible,
the coupling does not compensate for gross permanent misalignment.
Some people are of the opinion that since the coupling is termed flexible it
requires less accurate alignment. This is not so. This type of coupling
provides allowances only for unintentional, unexpected, but ever present
short periods of misalignment created by the inherent characteristics of the
units operation. It is because these flexible couplings are designed to
accommodate these forces that they do not fail as readily as bearings or
seals, which are not designed for any great amount of misalignment.

2.2

EFFECT ON BEARING, SEALS AND SHAFTS

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Stresses that accompany misalignment also have a severe effect upon

bearings, both antifriction and plain, thereby reducing their life. Proper
alignment cannot extend the natural life of an antifriction bearing.
Misalignment can certainly reduce their natural life. When the life of a
bearing is determined, it is done without misalignment forces being present.

2.3

SHAFT AND OTHER PARTS

Most mechanical seals are designed to function properly only when minimum
shaft deflection is encountered, thus, mechanical seals fail due to shaft
deflection created by misalignment.
Unlike other mechanical problems which begin as a minor deficiency and
grow into something quite noticeable and major, misalignment is as severe
the first revolution as it is when the machine finally fails. This is the case
when a machine does not shift due to misalignment forces. It is through this
minor deficiency that the major failure can stem. It is true that stresses from
misalignment are in direct proportion to the speed of the unit, with the
amount of initial misalignment remaining constant. Speed of unit should
generally dictate the tolerances allowed for alignment.
Operating
characteristics will also govern initial and operating alignment tolerances.
The following discussion of shaft alignment is dependent on keeping these
thoughts of mind.

3.0

FACTOR AFFECTING ON ALIGNMENT

Prior to discussing the particular procedure to be employed on a given unit,
there are several factors that may mechanics either dont understand or fail
to consider..

3.1

PIPING STRAIN
Practically all manufactures assembled units, both driver and driven on a
common base are factory alignment. This factory alignment only serves the
factory purpose to determine if and how the unit can be alignment within its
mechanical limits.
Factory alignment was supposedly obtained with the base in an absolutely
level, unstressed position, but when the unit grant and piping installed on it
many undue stresses are involved to disturbed the alignment.
For achieving the maximum possible factory aligned mechanical limit the unit
must be grout in a level foundation after that stage take a preliminary
alignment reading and record it.
Install all piping on the pump and electrical connection, checked and
measure the alignment distortion.
This will allow noting any movement of the shafts caused by stresses
imposed by the piping .
Stress relieving or some other means of eliminating these stresses may have
to be performed. Additional pipe supports may be required. If blinds have

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been placed in the lines during shut down, final alignment not be performed
until these have been removed.
Note: On a installed unit, when pump casing or piping removed for
maintenance purpose and at the time of reinstallation the piping strain can
again activate.

3.2

DOWEL PINS AND PUMP CASING JOINTS

On some unit dowel pins are provided for exact pump casing joint, because
it is very critical to the proper operation of the pump.
Manufacturers of these pumps require that this joint be evenly loaded to
insure proper operation of that unit. Most pump designs allow a space at
this joint. During the assembly of the pump, the mechanic equalizes this
space using feeler gages. From this point on in the installation and
alignment of the pump, this space should not be disturbed. However, some
mechanics unwisely use this adjustable joint to achieve proper alignment.
By doing this, there is danger of reducing axial impeller clearance at the tips
of the impeller vanes.

3.3

PUMP BEARINGS SUPPORT FIG. 1-1

If this type pump has an adjustable support leg under the inboard bearing, it
should not be secured until the case joint clearance has been equalized.
Then, with a dial indicator monitor, pull this leg down 1 to 3 mils (.001 - .
003). This will insure proper support of that bearing without placing an
undue strain on the casing.

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Fig. 1-1. Pump Bearing Support.

3.4

SOFT FOOTING
All driver support feet must be on the same plane. This condition is
extremely important and should be one of the first problem areas to be
checked. Drivers with four or more feet are the only ones to possible create
this problem. The trade name of that problem is known as Soft Footing .
Fig. 1-2 The soft footing created when one foot is slightly higher, or lower in
elevation. The soft footing created two major problems.

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Fig. 1-2. Soft Footing.

First exact alignment is very difficult to achieve, because this foot is
tightened down with the hold down bolt or nut it must do one of two things it
must spring the frame work and come down or it must break the foot. The
spring action create different alignment reading and condition of this sort is a
big handicap to the person doing the alignment.
Secondly, this condition of having a soft foot will introduce undue stress
within the unit itself. Bearings, mechanical seals, seals, and wear rings
suffer without need. Vibration, parts breakage, and ultimate failure is
possible when this condition is not resolved. The shaft no longer runs within
a line bored bearing housing, one is displaced in reference to the other.

3.4.1 METHOD FOR ELIMINATE SOFT FOOTING

First point for eliminate the soft footing, better used minimum number shims
rather than a bulk of small measurement shim because that can create a
spongy foot and that will behave as a soft foot.
Secondly if that is a permanent problem it must be eleminate by shimming
before the alignment. To eliminate the possibility of a soft foot, attach a dial
indicator to the support pedestal and set the indicator button on top of one of
the support feet. Zero the indicator. Now loosen the support nut and read
the indicator. If the indicator is deflected more than 3 mils move to the
adjacent foot and take a reading in the same manner. If the reading on the
second foot exceeds the first reading, the second foot should be shimmed.
Repeat this procedure until you obtain an indicator reading of less than 3
(0.003) mils when one foot is loosened and the others are tight.

3.5

MAGNETIC CENTER

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An electric motor is said to run in its magnetic center. This means that the
rotor is pulled into operating position by the magnetic force whenever the
motor is running. For this reason the coupling length can not be determined
when the machine is at rest unless a mark has been made, showing the
running position. If there is no mark the motor must be started to see just
where the shaft moves to, while it is running. Then the coupling spool is
made up to suit the distance between couplings for operating conditions.
Also lock the axial movement of the shaft while aligning, because that axial
movement differ the each face reading.

3.6

SHAFT DEFLECTION, COUPLIGN WEAR AND UNEVEN BEARING

WEAR

The shaft deflection affects the concentricity of the center line and causes
of misalignment.

The coupling wear in case of that when rotating only one coupling for
alignment can affects the parallelism of the two mating halves of coupling
and causes misalignment.

Uneven bearing wear again affects the concentricity of the shaft center
line, the same as in the case of shaft deflection.
The above mention factors must be checked before a alignment job started
by runout reading.
For taking run-out reading the dial magnetic base fixed on the base plate
and dial on the coupling OD and set it zero. The shaft is rotated and the
indicator observed to see if the permitted amount of deflection is not
exceeded.

3.7

HEAT GROWTH (PURPOSE OF HOT CHECK)

Since there is a temperature change in a unit from the shut down
temperature to the running temperature, we can also expect to have a
dimensional change caused by this change in temperature. Depending
upon the design and service of the unit, this change in dimension will vary in
amount and direction. This is why a hot check is vital to proper alignment.
As a rule, hot alignment is performed when there is a temperature difference
between driver and driven of 150 degrees or more. Here again this is a
general rule. Each particular unit will determine how it is to be aligned.
Basically there are two concepts about a hot check. One concept is to
achieve perfect alignment, unit aligned in cold and then put the unit on
stream. Once the operating temperature are reached, the unit is shut down
and alignment is again checked. Additional moves are made once the unit is
cold again to compensate for hot movement.
There are several
disadvantages to this method.
First is the fact that an additional shim change time will be required.
Time consumed for dimensional changes and shut down

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The second concept of hot alignment is that of knowing where the unit will
go. If the facts are not known as to the units movement, it is easy to second
guess the units movement, if the facts, or calculations, are correct as to
where the unit will move, the unit will align itself. If it does not, at least it will
move in the desired direction. One apparent advantage of this concept is
that it is possible not be forced into an additional shim changed based upon
hot readings. There is one limitation. If cold alignment is drastically off, as in
the case with a steam turbine driving a cold service pump, putting the unit on
stream should be done slowly and cautiously to allow warm up and
positioning of the shafts.
Nearly all units are aligned cold with allowances made for expected thermal
growth. Regardless of whether these allowances have been made or not, a
hot check should be performed. This check will confirm the hot position of
the shaft

4.0

ALIGNMENT TOLERANCES
Perfect alignment is the desired objection but in the practical field and in
many cases the achievement of (0.00) alignment reading is quite difficult and
time consuming job. So the alignments for a unit can accept with some
tolerances. Remember a stock set of alignment tolerances which are
suitable for all of industry just simply does not exist. As key a good
alignment tolerances for a given unit is one which permit the unit to run
without creating forces great enough to causes the components to fail
prematurely. According to that view forces generated by misalignment are
directly related to the speed of the shafts, it is logical to use speed as the
governing agent to establish alignment tolerances. Economics is the other
factor for establishing the acceptable tolerances. For example, a pump
which requires a new seal every six weeks would hardly warrant the time
required to establish perfect alignment. This is especially true when the
shafts can be placed within tolerance within a an hour or so. On the other
end of the spectrum is a unit which is not planned to come down in two
years. The extra time required to achieve perfect alignment is justified.
Some people in industry use the vibration caused by misalignment as the
criteria for alignment tolerances, but a practical expenses, that a very low
tolerances can be double without an appreciable change in the amplitude of
vibration.
Listed below are some tolerances that are based upon speed and generally
accepted in production industries.
The slow speed range will encompass the majority of electric and steam
driven units.
SLOW SPEED

3550 RPM & Below

5 Mils on OD
3 Mils on Face

HIGH SPEED

3600 RPM & Above

2 Mils (TIR) on OD

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1 Mil (TIR) on Face

Flexible coupling manufacturers describe the capabilities of their couplings
on the basis of maximum angular misalignment, among other things. This is
the amount at which their coupling will still function. This can hardly be used
as the criteria for establishing alignment tolerances.

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5.0

MISALIGNMENT DETECTION
It should be noted that misalignment can be detected while the machine is in
operation.
Forces caused by misalignment will create vibration as
mentioned before. The characteristics of this vibration is what can be used
to determine a condition of misalignment. It specially is the direction of this
force that is the key, a high axial force. A high axial force is generated when
the misalignment is primarily angular. This is influenced to a large extent by
the type of coupling transmitting the forces. When the type of mis-alignment
is primarily OD, or parallel, the axial forces subside and a larger radial force
is evident as shown in Fig. 1-3. To determine where the forces are and in
what direction they are in is a simple task provided an adequate instrument
is available.

Fig. 1-3. A is measuring Axially and B is measuring radially

vibration for detecting misalignment.
The most effective manner to confirm misalignment is with dial indicators. As
was mentioned earlier, the alignment of two shafts can be well outside the
tolerances normally established and still not produce an alarming vibration
level. This is due primarily to the type coupling employed and the type of
misalignment in the unit.
Each type of misalignment has its own
characteristics of vibration and dial indicator readings.

6.0

TYPES OF MISALIGNMENT
Basically, there are three conditions that may exist for misalignment.
As shown in Fig. 1-4, the shaft are parallel to each other but offset
somewhat. This condition is known by several terms.

6.1

PARALLEL MISALIGNMENT

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But more commonly by parallel or, better yet OD. Shaft center lines do not
intersect to correct for this condition movement is made for one half the TIR
of OD indicator.

Fig. 1-4. OD Displacement.

6.2

ANGULAR OR FACE MISALIGNMENT

This type of misalignment is represent by Fig. 1-5 should be noted that the
shaft center lines intersect at only one point, as opposed to being concentric.
Any adjustments to this condition should be made against TIR of face
Indicator.

Fig. 1-5. Angular or Face Displacement.

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6.3

MISALIGNMENT BY COMBINATION OF ANGULAR & PARALLEL

That condition involves a combination of these two condition as shown in
Fig. 1-6.

Fig. 1-6. Angular Parallel Displacement.

In order to make the task of shaft alignment more interesting, we must cope
with these conditions in both the horizontal plane, looking at the side of the
unit, and in the vertical plane, looking down on the unit. Again, the utopia is
to get these shafts on a concentric center line throughout their entire length,
or TIR OD of O and TIR FACE of O in both planes during the hot check.
Depending upon speed and unit, deviation from the exact alignment can be
tolerated.
The specific procedure that should be, or better yet can be, used to align
the shafts will be governed primarily by the unit. Since there is an unlimited
number of different sizes and types of units requiring alignment, lets narrow
this down to three categories. Each category is a separate procedure; two
indicator, Reverse Indicator, and Dynamic to Static Methods.

7.0

ALIGNMENT RECORDS
Regardless of the procedure employed for shaft alignment, a sound set of
records should be maintained for each particular unit being aligned. These
records not only aid the mechanic during the aligning process, but also serve
as permanent record for future alignment.
The record shown in Fig. 1-7 was designed for one particular procedure of
alignment, the Indicator Reverse Method. With very minor alternations, this
same form can be used for each particular procedure discussed in this study.
The majority of the form is self-explanatory. However, on each procedure
the reference of direction is essential. This form provides for the location of
North. Any direction is suitable but North is generally used. Direction will
prove to be of great value when determining lateral shifts. Inside the circles
are located a portion of an arrow. It should be completed to show the
direction of rotation of the unit, which is also the direction the shafts were
turned to obtain Indicator readings.

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Fig. 1-7. Alignment Record Sheet.

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