Basic Shaft

Alignment
Workbook
for industrial rotatin~ n1achincrv
L •

;?=;,~
~~ft
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. ____ ..-
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 Basic Shaft Align111ent
Workbook
Fourth Edition

Text, illustrations, and photographs by John Piotrowski

copyright © 1990-1998 • Turvac Inc.

All Rights Reserved

Dedicated to Bobbie Jo, Tracy, Paula, Peter, Magdalena, joseph, Robert,

Betty and the many people who struggle with this problem on a day to day
basis and receive no recognition for a job well done.
Basic Shaft Alignment Workbook

Preface
W elcome to the introductory book on shaft alignment of rotating
machinery! The purpose of this book was to gi ve the beginning student an
overview of the basic topics in shaft alignment and was meant to comple-
ment The Shaft Alignm ent Handbook (579 pgs., published by Marcel
Dekker Inc., New York, N Y) which, for the beginner, was a little more
material than perhaps was needed for j ust a preliminary understanding of
thi s subject.
This Workbook is primarily used as a training guide for people attend-
ing shaft alignment training courses and then, hopefully as a field guide for
the trades person, technician, foreman, and engineer doing machinery
alignment in the field. I have tried to keep the text to a minimum and
portray as many of the alignment procedures and techniques in graphical
form or in pictures as much as possible.
Shaft alignment looks deceptively simple to do but in reality, it 's a
struggle between you and the machine. B y applying a little bit of intelli-
gence, patience, and perseverance, usually everything straightens out in th e
long run. Best of luck to all of you who arc willing to give this a try!
 Table of Contents

The Importance of Shaft Alignment 1

Shaft Alignment Overview 13

Before You Start ... 21

Measuring the Shaft Positions 29

Shaft Alignment Graphing Techniques

Reverse Indicator graphing/modeling 37
Face-Peripheral graphing/modeling 49
Shaft to coupling spool graphing/modeling 55

Positioning the Machinery 59

 The Importance of Shaft Alignment

The Importance of Shaft Alignment

The most frequently asked questions by manag-

ers, engineers ,foremen, contractors, and trades
people concerning the subject of shaft (mis)alignment
and its importance in maintaining industrial rotating
machinery are discussed. The first part of this work-
book will review what shaft misalignment is, a brief
summary of the alignment procedure, why the quality
of alignment needs to be improved, the consequences
of misaligned machinery, and the frequency that
alignment should be checked.

What exactly is shaft align me lit? rigidly coupled together.

In very broad tenn s, shaft
misalignment occurs when the
centerlines of rotation of two (or
more) machinery shafts are not in
line with each other. As simple as
that may sound, there stil l exists a
considerabl e amount of confusion to
people who are just beginning to
study this subject when trying to
precisely define the amount of
misalignment that may exist
between two shafts fl exibly or
How accurate docs the
alignment have to be? How do you
measure misalignment when there
are so many different coupling
designs? Where should the mis-
alignment be measured? Is it
measured in terms of ... mils,
degrees, mill imetcrs of offset,
arcseconds, radians? When should
the alignment be measured ... when
the machines are off-line or when
they are running?
Ba~ic Shaft Alignmcnl Workbook

In more precise 1enns. shaft shafl and 1hc projec1ed cenlerline of

misalignmellf is the deviation of
relmive shaft position from a
colinear axis of rotation measured
at the poims of power transmission
when equipment is mnning at
normal operating conditions. To
better understand this definition,
let's dissect each part of thi s
~tatemen tto clearly illustrate what's
involved.
The deviation of relati ve
shafl position accounts for the
measured difference belween the
actual centerline of rotation of one
rolation of I he other shaft. Pigure I
shows a typical misalignment
situation on a motor and a pump.
r or a flexible coupling to
accept both parallel and angular
misalignment there must be at least
two points where the coupling can
'flex' or give to accommodate the
misalignment condition. By
projecting the axis of rotation of the
motor shaft toward the pump shaft
(and converl>ely the pump shafl
rotational axis toward the mo1or
shafl) there is a measurable devia-

m<lumum olu~nm~nl
tlenutwn on t~n ltPrr

,_ )
~
/
dn'tcr off-.ct
driven off\Ct
(m m1l')

(on nul>)

Figure I. I low misalignment is defined

2

The goal of the person doing the alignment is to posi-
tion the machinery casings such that all of these de-
viations are below certain tolerance values.
ti on between the projected axes of
rotation of each shaft and the actual
shaft cen terlines of each shaft where
the power is being transmitted
through the coupling from one
'flexing' point to another. Since we
measure misalignment in two
different planes (verti cal and
hori zontal) there will be four
deviations that occur at each
coupling. fn the example shown,
notice that there is a horizontal
deviation and a vertical deviation at
the point of power transmission on
the motor and a hori zontal deviation
and a vertical deviation at the point
of power transmission on the pump.
The goal of the person doing the
alignment is to position the machin-
ery casings such that all of these
deviations are below cerwin
tolerance values. A tolerance guide
is shown on page 16 that will help is
establishing a goal for the people
who are doing the alignmen t.
The Imponancc of Shaft Alignment
The last part of the definition
of shaft misalignment is probably
the toughest to achieve and usually
the one aspect of alignment that is
most often ignored. When rotating
equipment is started, the shafts will
begin to move to another position.
The most common cause of this
movement is due to temperature
changes that occur in the machinery
casings and therefore this movement
is commonly referred to as hot and
cold alignment. These temperature
changes are caused by friction in the
bearings or by thermal changes that
occur in the process liquids and
gases. Movement o f machinery
may also be caused by process
reacti on moments in attached piping
or counter-reactions due to the
rotati on o f the rotor, something
similar to the forces you feel when
you try to move you arm around
with a spinning gyroscope in your
hand.
3
Basic Shaft Alignment Workbook
What is the objective of accurate
alignment?
Simply stated, the objective
of shaft alignment is to increase the
operating lifespan of rotating
machinery. To achiev e this goal,
machinery components that are
most l ikely to fail must operate
within their design limits. Since th e
components that arc most likely to
fail are the bearings, seals, coupling,
and shafts, accurately aligned
machinery will achieve the follow-
ing results ...
• Reduce excessive axial and radial
forces on the bearings to insure
longer bearing life and rotor
stability under dynamic operating
conditions.
• Eliminate the possibility of shaft
failure from cyclic fatigue.
• Minimize the amount of wear in
the coupling components.
• Minimize the amount of shaft
bending from the point ofpower
transmission in the coupling to the
coupling end bearing. Maintain
proper internal rotor clearances.
• Lower vibration levels in machine
casing~~ bearing housings, and
4
rotors (*note ... frequently, slight
amoums of misalignment may
actually decrease vibration levels in
machinery so be cautious about
relating vibration with misalign-
ment).
What are the symptoms of mis-
alignment?
Misalignment is not easy to
detect on machinery that is running.
The radial forces transmitted from
shaft to shaft are typically static
forces (ie. uni-directional) and are
difficult to measure externally .
Disappointingly, there are no
analyzers or sensors that you can
place on the outside o f a machine
case to measure how much force is
being applied to the bearings, shafts,
or couplings. Consequently what
we actually sec arc the secondt1ry
effects of these forces which exhibit
many of the following symptom s...
• Premature bearing, seal, shaft, or
coupling failures.
• Excessive radial and axial
vibration. (*Note ... tests have
shown that different coupling
designs exhibit different types of

vibration behavior. It appears that
the vibration is caused by the
mechanical action that occurs in the
coupling as it rotates).
• High casing temperatures t lf or
near the bearings or high discharge
oil temperatures.
• Excessive amount of oilleakoge at
the bearing seals.
• Loose foundation bolts (refer to
'soft foot' later in this book).
• Loose or broken coupling bolts.
• The coupling is hot immediately
after unit is shutdown. If it is an
elasromeric type, look f or rubber
powder inside the coupling shroud.
• The shaft runout may hal'e a
tendency to increase after operating
the equipmem for some time.
• Simila r pieces of equipment are
vibrating less or seem to have a
longer operating life.
• Unusually high 1111111ber of cou-
pling failures or they wear quickly.
• The shafts are breaking (or
cracking) at or close to the inboard
bearings or coupling hubs.
• Excessive amoums of grease (or
oil) on the inside of the coupling
guard.
Importance of Shaft A lignment
What happens to rotating machin-
ery wh en it 's misaligned ll little bit,
or m oderately, or even ... severely?
The drawing shown in figure
2 illustrates what happens to
rotating machinery when its
misaligned. Albeit, th e misalign-
ment condition shown here is quite
exaggerated, but it serves to indicate
that rotating machinery shafts will
undergo distortion (ie. bending)
when verti cal or lateral loads arc
transferred fro m shaft to shaft.
Please do not m isinterpret th e
drawing ! It is fully understood that
fl exibl e couplings do just what they
are desig ned to do ... they flex to
accommodate slight misalignment.
But the shafts arc flexible too, and
as the misalignment becomes more
sev ere, the more the shafts begin to
flex also. Keep in mind that the
shafts arc not permanemly bent,
they are just elastically bending as
th ey undergo rotation.
Notice also that the pump
shaft in thi s example is exerting a
downward force on the inboard
motor bearing as it tries to bring the
motor shart in line with its center-
line of rotation. Conversely, the
5
Bal>ic Shaft Alignment Workbook

centerline of motor bearings

I
centerline of pump beurings mechanical \Crtl
or packing

• une' en rolor 10 "a lor air gap
• C)Ciic faliguc of ro10r componeno.
• excessive rad1al and """' force<
lransmined 10 bearing.<
• >hafl .cal rubbing heavier on one ~ide
• une,en Impeller to diffuser clearance
• C)dic fa1igue or rotor componenl<
• t\CC'-.'I"e radial and axial force'
oran,mined 10 bearings
• mcchonical seal rotating member not
running concentric to stationary ~cnl
member

Figure 2. Rotor distortion caused by misalignment.

6
 Importance of Shafl Alignment

motor shaft is exerting an upward
force on th e inboard pump bearing
as it tries to bring th e pump shaft in
line with its centerline of rotation.
If the forces from shaft to shaft arc
great enough, the force vector on the
outboard bearing of th e motor may
be in the upward directi on and
downward on the outboard bearing
on the pump. Perh aps the reason
why misaligned machinery may not
vibrate excessively is due in part to
th e fact th at these forces are acting
in the same direction. Forces from
imbal anced rotors for instance, will
change their direction as the ' heavy
spot' is continually moving around
as th e shaft rotates, thus causing
v ibrati on (ie. motion) to occur.
Shaft misalignment forces do not
move around, they usually act in
one direction only.
The chart in figure 3 ill us-
trates the estim ated time to fa ilure
of a typical piece of rotating
equipment based on varying
alignment conditions. The term
'failure' here implies a degradation

1000

c:
0
~
(j; 100
a.
0

"':::>0
:::>
.s
c0 10
(.)

0
"'
:5
c:
0
E

0.
0.2 50 100

misalignment (mils/inch)

Figure 3. Estimated time to failure of rotating machinery due to misalignment.

7
Basic Shafl Alignment Workbook
of any critical component of the
machine such as the seals, bearings,
coupling, or rotors. The data in this
graph was compiled from a large
number of case histories where
misalignment was found to be the
root cause of the machinery failure.
flow much time does it take to do
each step in the alignment proce-
dure?
There arc eight basic steps in
the overall alignment joh.
J. Preparation - tools, people,
training.
2. Obtain relevant information on
the machine being aligned. Arc
there any special tools needed to
measure the alignment or reposition
the machines? Do the machi nes
move from off-line to runn ing
conditions? If so, how much and ...
do you have to purposely misalign
th em so they move into alignment
when they ' re running?
3. Before you begin working on a
machine remember ... Safety First!
Tag and lock out the machinery.
4. Preliminary checks : runout, 'soft
foot', coupling OK?, bearings OK?,
foundation OK?, baseplate OK? Is
8
the piping putting a strain on the
machines?
5. M easure the shaft positions. Arc
they within acceptable alignment
tolerances?
6. Decide who needs to be moved
(which way and how much) and
then physically reposition the
machinc(s) vertically, laterally and
axially. After you've made a move,
go back to step 5 and check to sec
that the machines really moved the
way you hoped they did.
7. Instal l coupling and check for
rotational freedom of drive train if
pos ible. Install coupling guard.
8. Run and check the machinery.
Later on, we ' ll examine each
of these steps in greater detail but
for now, let 's look at the approxi-
mate amount of time it takes to
perform each of these tasks to give
you a feel for how much time thi s is
going to take.
The graph in figure 4 shows
the average amount of time taken to
do steps 2 through 8. Step I is not
on the graph since procuring all the
necessary tools and training
everybody who 's involved can take
a considerabl e amount of time to
 Importance of Shaft Alignment

600

500
D Small Machont<y
(IJI)IO 100 hp)
• Medium Machinery
(100500 hp)

• ""·~.:r

-
200

nl
100

000
ni l Ill n• l n•• i1
;; .p ~ :s ~ t'
~ ,# -~ $ ~
-~ t>
....,<f (j 8i ~
II t;
'17 $'
~
~
~ Q #
I'*
t' ·t> 1: .~r::
~ ,_f q ! ·:::;:
0 .f!i
~ ~
~
·t> i §I
.$
8i
~
$i ~
~ t!i
(j

Figure 4. Estimated time to perform alignment procedures.

complete. As you can sec, the two know what they are doing and they
most time consuming tasks in the have to have a goal to shoot for.
alignment process arc ... performing They also require access to all of the
the mechanical integrit y checks and tools needed to do the j ob and the
moving the machinery to align the tools must work properly. If your
shafts. It is not uncommon for company purchased an expensive
accurate alignment to take from 3 to alignment measurement system that
8 hours, assuming everything goes stays locked up in a cabinet, it 's not
just ri ght! doing anyone any good if they can' t
use it when they need it.
How can I reduce the amount of It is also important to have an
time it takes to do alignment alignment system that can provide
properly? you with alternative movement
First, the people who arc solutions when repositioning the
al igning the machinery have to machinery. The key to success fully

9
Basic Shaft A l ignment Workbook
The key to successfully aligning machinery comes
from having the ability to arrive at a solution that is
possible to p erform and minimizes the required move-
ment at the feet.
aligning machinery comes f rom
having the ability to arrive at a
solution th at is possible to perform
and minimizes the required move-
ment at th e feet. A ccurately
calculating required movement at
the machinery feet is useless if you
can' t move the machine the am ount
your alignment system is telling
you.
How often should alignment be
checked?
As previousl y mentioned,
rotating machiner y can move
around immediately after it has been
started. T his is fairly rapid move-
men t and the shafts eventually take
a somewhat permanent position
after the thermal and process
conditi ons have stabilized (any-
where from 2 hours to a week in
some cases). However there are
slower, more subtl e changes that
occur over longer periods of time.
10
M achinery w ill slowly ch ange its
position for the same reason your
d ri veway buckl es, or your building
foundati on cracks. Settling of base
soils undern eath the machinery will
cause entire foundations to shift. A s
the foundatio ns slowl y move,
attached piping now begins to pull
and tug on the machinery cases
causing the equipment to go out o f
alignment. Seasonal temperature
changes also cause concrete,
baseplates, piping, and conduit to
expand and contract.
It is recommended that new ly
installed equipment be checked for
any alignment changes anywh ere
from 3 to 6 months after operati on
has begun. Based o n w hat you find
during the first o r second alignment
'checkup', tailor your alignment
surveys to best suit the individual
drive trains. On the average, shaft
alignment on aU equipment should
be checked on an annual basis.
 lmponancc of Shaft Alignment

Don't feel too embarrassed as you coupling hub runout information,

read this because you're definitely the final alignment data, the moves
not the only person who hasn't made on the machinery, and the
checked your machinery since it has final alignment tolerance. Don't be
been installed. satisfied with an answer like ...

How much money should I be We used la~rs and

spending on tools and training? dial indicators.

A good rule of thumb is to

invest I % of the total replacement
cost of all your rotating machinery
on alignment tools and training on
an annual basis. For example, if
you have 20 drive trains in your
facility valued at $5000.00 each
(total $100,000.00) then you should
Dial indicators and laser!> don't
invest $1000.00 on alignment every
move machinery, people do.
year. Thi s expendi ture should only
cover tools and training and should
not encompass the time and
materials required to do alignment
jobs.

How do I know if th e contractors I

hired to install my machinery are
doing the alignment properly?
Include some clause in your
contract that requires them to
provide you with the initial align-
ment data, 'soft foot ' conditions
and the corrections made, shaft and

11
Basic Shaft Alignment Workbook

Notes ...

Sketches ...

12
 Shaft Alignment Overview

Shaft Alignment Overview

• types of alignment cond itions
• definin g misalignment
• determ ining alignment tolerances
• the eight ste ps of alignment

13
Basic Shaft Alignment Workbook

The two basic types of misalignment conditions

parallel misalignment

angular misalignment

'real world' misalignment usually exhibits a

combination of both parallel and angular
shaft centerline positions

14
 Shaft Alignment Overview

Defining misalignment ...

Misalignment is the deviation of relative shaft position

from a colinear axis of rotation measured at the points of
power transmission when equipment is running at
normal operating conditions.

15
Basic Shaft Alignment W orkbook

How to determine your

alignment tolerance

Find the largest of the four

top view deviations and divide it by
the distance between the
points of power transmission
to determine the maximum
misalignment deviation.

side view
points of power transmission

~
here's 1hc distance between 1h:__/.
points of power transmission
here's Ihe larges1of 1hc
four clcvia1ions

for example ...

If the largest of the
four deviations is ...
6 mils <0.006''l
... and the distance between the
1.5 mils/inch
4" is your maxlmum deviation
power transmission points are ...

16
 Shaft Alignment Overview

Misalignment Tolerance Guide

angle
mils per inch
2.0 .,....---- - - - - - - - - - - - - - - - -- ---, I
~
- 0.10
c
0
·;:;;
iii ·~ 1.5
realignment necessary
_....
CVl
.Q
ro-
~
008

·;;: (i)
~~
0.06
1.0
EO.
::>-
E~
·x .s 004
roo
Eo.
acceptable
(i) 0.5
£ 0.02
'Q)

excellent
2 4 6 8 10 12 14 16 18 20 22 24 26
speed (RPM x 1000)

17
Basic Shaft A lignment Workbook

The eight steps of shaft alignment

1 Purchase or fabricate the necessary tools and measuring devices.
Insure that the people involved in the alignment process have been ade-
quately trained on ... various alignmen t procedures and techniques, how to
care for delicate measuring instruments and how to use them, what tools
should be used to reposition the machinery, whether a machine is really
ready to be al igned and operated or whether it should be removed and
rebuilt, when a baseplate or foundation has deteriorated to the point where
repairs are needed or corrections should be made, correc ting problems that
exist between the underside of the machine case and the points o f contact on
the baseplate, how to check for static and dynamic piping stress, what the
desired 'off-line' machinery positions should be, how to measure off-line to
running machinery movement, what the alignment tolerance is for the
machine they are working on, and how to keep records on what was done
during the alignment job for future reference.

2 Obtain relevant information on the equipment being aligned. Are

there any special tools needed to measure the alignment or reposition the
machines? Do the machines move from off-l ine to running conditions? 1f
so, how much and ... do you have to purposely misalign them so they move
into alignment when they' re runn ing?

3 Before you begin working on any machinery remember ... Safety

First! Properly tag and lock out the equipment and inform the proper
people that you're working on the machine.

4 Insure that you perform these preliminary checks: inspect the

coupling for any damage or worn components, find and correct any prob-
lems with the foundation or baseplate, perform bearing clearance or
looseness checks, measure shaft and/or coupling hub runout, find and

18
 Shaft Alignment Overview

correct any 'soft foot' conditions, eliminate excessive piping or conduit

stresses on the machines.

5 Rough align the machinery and check that all of the foot bolt!> arc
ti ght. Then, accurately measure the shaft positions using sensori> such as
dial indicators, lasers, proximity probes. angular or linear resolvers, or
CCD's (charge couple devices). From this data, detem1ine if the machinery
is within acceptable alignment tolerances.

6 If the machinery is not within adequate alignment tolerances ... first,

determine the current positions of the centerlines o f rotation of alithe
machinery; then, ob erve any movement restrictions imposed on the
machines or control points; next. decide whi ch way and how much the
machinery needs to be moved; and fina lly, go ahead and physically reposi-
tion the machine(s) in the vertical , lateral, and axial directions. After
you 've made a move, be sure to re-check the alignment as described in step
5 to determi ne if the machines reall y moved the way you hoped they did.
When the final desired alignment tolerance has been satisfied, record the
final alignment position for future reference. the orientation of the · ~oft
foot' shim correcti ons. and the final shim packs used to adjust the height o f
the machinery. If lateral and axial jack screws exist. lightly ' pinch' these
screws against the sides of the machinery case, lock them in place. and
make sure the foot bolts are secured.

7 Install the coupling (assuming it was disai>sembled for inl>pection)

and check for rotational freedom of drive train if possible. Install the
coupling guard and make any final checks on the drive train prior to
removing the safety tags.

8 Operate th e unit at normal conditions checking vibration levels,

bearing temperatures and other pertinent operating parameters.

19
 Be fore You Start ...

Before you start ...

• dial indicator basics
• check for runou t
• 'soft foot'

21
Basic Shaft Alignment Workbook

Dial Indicator Basics

bottom plunger type back plunger type

stem moves outward ... stem moves inward ...

needle rotates counterclockwise needle moves clockwise

22
 Before You Stan

Checking shaft and/or

coupling hub 'runout'
keep the dial indicator still

rotate this shaft

through 360 degrees

the dial indicator can he mounted like this also/

23
 Basic Shaft Alignmenl Workbook

'Runout' problems usually fall into

one of these three catagories ...

Coupling hub bored

off center

Bent shaft

Coupling hub
'skew' bored
lhe 'high' spots
aren'l in the
same place

Recommended Runou t Guidelines

Machine Speed Maximum a llowable
(RPM} Total Indicated Runout (T.I.R.)
0-1800 4 mils (0.004")
1800-3600 2 mils (0.002")
3600 and up less than 2 mils

24
 Before You Stan ...

What is 'soft foot' and why is it

necessary to correct it?
Soft foot de cribes any conditio n where poor surface
contact is being made between the underside of the machine
casing 'feet' and the points where the feet touch the baseplate o r
frame.
Quite often the underside of the 'foot' and the baseplate
contact area are not parallel and exhibit a very complex 'wedge'
type of condition. Other times the two surfaces are parallel but
a gap exists somewhat similar to the short leg of a four legged
chair. It is not uncommon to see three of the feet 'toe up' and
the fourth foot 'toe down'.
By ig noring this problem, tightening the bo lts without
correcting the 'soft foot' condition will serve to disto rt the
casing and put undue strain on the bearings and ro tating ele-
ment and cause a considerable amount of frustratio n when
trying to align machinery.

25
 Basic Shaft Alignment Workbook

Measuring the gap conditions

around all of the foot bolts
Step No.1
Loosen all the foot bolts
holding the machine case to
the baseplate, frame, or
foundation. Remove any
dirt, rust, or old shim stock
from underneath each of the
feet. If necessary, use some
sandpaper or emerypaper
(approximately 80 grit) to
clean the surfaces on the
underside of the machine
'foot' and the points of
contact (sometimes called
the 'pads') on the baseplate.
'Finger tighten' the bolts but
do not tighten them securely.

Step No.2
Use a set of feeler gauges
or a dial indicator to 'map'
the soft foot condition as
shown at the right.
Determine where the
contact is really being
made and then record the
gap between the underside
of the machine casing and
the baseplate around the
contact area at each foot
point.

rc
~

8 3 mils
~

1 0 8mils

26
 Before You Start

Correcting the 'soft foot' problem and

verifying that it has been eliminated

Step No.3
Eliminate the 'soft foot' by
building a 'shim wedge' and
installing the special wedges
under each foot that needs
correction.

Step No.4
Check all the foot poinb
for 'lift' with a dial
indicator by ...
I - tightening all the foot
bolts
2 - zero a dial indicator on
the topside of one corner
near th e foot bolt and then
carefully loosen the bolt
and watch the indicator for
any movement
3 - retighten that bolt and
move the dial indicator
set-up to the next foot
4 - repeat the procedure at
each of the feet recording
Lhe amount of lift at each
foot

None of the feet shoud

rise more than 0.002"
to 0.004"
Note : Once the soft foot shims have been installed, they should remain
there for the rest of the alignment procedure.

27
 Measuring the Shaft Positions

Measuring the shaft positions

• 'rough' alignment methods

• face-peripheral technique
• reverse indicator technique
• shaft to coupling spool technique
• checking bracket 'sag'
• tips for getting good readings

29
Basic Shafl Alignmenl Workbook

'Rough' alignment methods

the 'calibrated eyeball'

the straightedge method

the taper or feeler gauge method

30
 Measuring the Shaft Positions

Face - Peripheral technique

face indicator

Procedure ...

l- Attach the alignment

bracket firmly to one shaft and
position the indicator(s) on the
indicator readings log
face and perimeter of the other
shaft. 0
2 - Zero the indicators at the 12
o'clock position.
3 -Slowly rotate the shaft and
bracket arrangement through + 15
90 degree intervals stopping at
the 3, 6, and 9 o'clock
positions. Record each reading
I
(plus or minus).
4 - Return to the 12 o'clock
position to see if the
indicator(s) re-zero.
5 - Repeat steps 2 through 4 to
\peripheral
readings
+22 face
readings

verify the first set of readings.

31
 Basic Shaft A lignment Work book

Reverse Indicator technique

Driver Driven

Procedure ... indicator readings log

1- Attach the alignment bracket(s) Driver

firmly to one (both) shaft(s) and 0
position the indicator(s) on the
perimeter of the other shaft.
2- Zero the indicator(s) at the 12
o'cloc k position.
3 - Slowly rotate the shaft and
bracket arrangement through 90
-260 -47
-73
degree intervals stopping at the 3, 6,
and 9 o'clock positions. Record each
reading (plus or minus). Driven
4 - Return to the 12 o'clock position 0

-5 0 +38
to see if the indicator(s) re-zero.
5- Repeat steps 2 through 4 to veri fy
the first set of readings.
6 - If one bracket was used , mount
the bracket onto the other shaft and
repeat steps 1 through 5.
+33
32
 Measuring the Shaft Positions

Shaft to coupling spool technique

Procedure .•.
indicator readings log
1- Attach the alignment bracket(s) Driver to spool
firmly to one (both) shaft(s) and 0
position the indicator(s) at some
point along the coupling spool with
the indicator(s) touching the
outside diameter of the spool.
2- Zero the indicator(s) at the 12
o'clock position.
+320+15
+47
3 - Slowly rotate the shaft and
bracket arrangement through 90
degree intervals stopping at the 3, Driven to spool
6, and 9 o'clock positions. Record
each reading (plus or minus). 0
4 - Return to the 12 o'clock position
to see if the indicator(s) re-zero.
5 - Repeat steps 2 through 4 to
verify the first set of readings.
6 - If one bracket was used, mount
the bracket onto the other shaft and
-·0-31 -39
repeat steps I through 5.

33
Basic Shaft Alignment Workbook

Checking 'bracket sag'

first ... zero the indicator

at 12 o'clock
then ... rotate the
pipe, bracket, and
dial indicator
assembly 180
degrees

finally ... record the reading

on the bottom

34
 Measuring the Shaft Positions

Validity Rule ...

(left) + (right) = bottom

for example ...

0

,o~
-25

Causes for deviations to the validity rule ...

~
&21
Problem...
The dial indicators are not
stopping exactl y at the 3, 6, and I
or 9 o'clock positions. Lb. ~

Solution ...
v_ ;)o} ~·
·,;~
-0 ..J;,-
accurately measure 90 degree
angles or use a twin spirit level

Problem ...
the dial indicator stem is not
perpendicular to the surface

Solution ...
insure that indicator is
perpendicular to the reading surface

Problem ...

0
the dial indicator stem traverses an elliptical path
.T . whalthe indicOIO< p31h really '5«5'

~ ·~
Solution ...
there is nothin

35
Basic ShafJ Alignment Workbook

Tips for getting good readings

rotate twice around the shaft,

record the readings at each ~ 0 average the readings
l/4tu m f{; i 0

x.a~,
,~{:!;
100-5 - 15
- 16 ..

position the indicator so the stem

is about l/2 of its total travel

Watch the indicator

through the entire
360 degrees of
rotation.

Ooops ! the stem

'bottomed out'

36
 Shaft Al ignment Graphing Techniques

Shaft Alignment Graphing

Techniques

Reverse Indicator Graphing Method

37
Basic Shaft Alignment Workbook

Setting up the graph

Measure the distances between the inboard and
outboard feet on both machines, the distance from the
inboard feet to the points where the dial indicator stems
are touching the shafts, and the distance between the
dial indicators.

motor

~ 14- I" per division

Accurately scale the distances measured

above onto the graph paper.
*Note: The scale can be I", 2", 3", 10" per division. Select
the smallest scale factor that fits the entire drive train onto
the graph paper.

38
 Sh:tfl Alignment Graphing Techniques

Prepare two graph sheets for

the two viewing planes

Side View Top View

motor pump motor pump

up south

Measure the shaft positions

Take a set of reverse indicn~or readings and compensate
the readings for the amount of sag in the bracket.
MOTOR PUMP
0 Field readings 0

-1 20
T -24 -300T-10
R
sag
R

'>4 Jt -40
8 8
- 6 0

0 J;a ': 4. 0

-80·20 -260T -S
Compensated 8
R -6

-28 readings .32

39
Basic Shaft Alignment Workbook

Why the dial indicator reads twice the actual centerline

to centerline distance as it traverses from the 12 o'clock
to 6 o'clock position on the circumferential readings.

Side View

The dial indicator ·sees· both of these distances

when it traverses from one side to the other.

End View

c:too:rlinc o( rocJ~ ion

shaft bcina: roi1Ued with pcriphen.l readings taken

indicator and atia.nmenl on lhiJ$ba.ft
brad:t1 an~K.hod to i1

40
 Shaft Alignment Graphing Techniques

Setting up the Driven machine

centerline for vertical movement
Instructions ...
If the bottom reading on the Driven shaft was
negative ... start at the intersection of the graph
centerline and the dial indicator position line and
mark a point directly above the graph centerline an
amount equivalent to half the bottom reading using
the graph division lines as I mil each (the scale can
be 2, 3, 5, 10, or 20 mils as long as the entire
Driven machine shaft centerline fits on the graph).
If the bottom reading was positive ... start at the
intersection of the graph centerline and the dial
indicator position line and mark a point directly
below the chart centerline an amount equivalent to
half the bottom reading.
Position the Driven machines shaft centerline to
go through the marked point on the dial indicator
position line and the point where the graph
centerline and the alignment bracket pos ition line
intersect.

for negative boUom readings •..

0
~ take half of
~f._ ~:iJading
-18 plot it here

extended -
pump
centerline

extended
pump
centerline

tott.tft !Mdi.t l~l.,.; •hmlhe dlall~l-'

read"'fooehc pu.lflp ~lldirla mhl"!-.

41
Basic Shaft Alignment Workbook

Setting up the Driver machine

centerline for vertical movement
Instructions ...
If the bottom reading on the Driver shaft was
negative ... start at the intersection of the graph
centerline and the dial indicator position line and
mark a point directly above the graph centerline an
amount equivalent to half the bottom reading using
the graph division lines as I mil each (the scale
can be 2, 3, 5, 10, o r 20 mils as long as the Driver
machine shaft centerline fits on the g raph).
If the bottom reading was positive ... start at the
intersection of the graph centerline and the dial
indicator position line and mark a point directly
below the chart centerline an amount equivalent to
half the bottom reading.
Position the Driver machines shaft centerline to
go through the marked point on the d ial indicator
position line and the point where the graph
centerline and the alignment bracket position line
intersect.

for negative bottom readings ... for positi.-e bottom readings ...
0
F-"::. 0

8
take half of
,' I
~nlnl_g)
this reading d I
take half of
~:i:;ading
·actuar -18 plot it here + 18 -:_j plot it here

motor
centerline
• 1wff'llwcliJ!IIOdltal(lfi\
~OIIlhe~

42
 Shaft Alignment Graphing Techniques

The four possible alignment

graph configurations are ...

motor

motor

43
 Basic Shaft Alignment Workbook

Setting up the machinery centerlines for lateral

movement (ie. side to side changes)
Basically, the principles used to set up the two machinery shafts in the TOP VIEW 10
detcnnine the amount of lateral movement needed are identical to the instructions
previously covered for the SLOE VlEW. The o nly element that changes is the viewing
direction. Since you can easily become confused remembering how you were oriented, it
is recommended that you use compass directions (north, south, east, west) nuher than left
and right when working in the TOP VIEW.
First, zero the dial indicator readings on the side of the machinery shafts that represents
the direction at the top of your graph paper. You can do this mathematically with the
complete set of readings captured or, you can rotate the bracket(s)/indicator(s) over to the
side of the shaft(s) that represent the di rection at the top of your graph paper, zero the
indicator(s) there and rotate the shaft(s), bracket(s). and indicator(s) 180 degrees to the
other side and record the readings.

0
MOTOR PUMP

Here's a complete set of readings

after they have been compensated for
bracket sag. -80 N _
T
0
B
·20
Compensated
readings
-6 S

_
T

B
N ·26

28 32
Here's the same set of readings as
above but the indicator was zeroed on MOTOR PUMP
top and swung directly to the bottom 0

00 -· oo-~
and then zeroed on the south side and
swung over to the nonh side. Notice
that the mathem atical difference
between the south and nonh readings
o n both th~ motor and the pump in the
complete set of compensated read ings -28 -32
are the same.

Instructions ...
If the side reading (N, S, E, W) on the either shaft was negative ... stan at the
intersection of the graph centerline and the dial indicator position line and mark a point
direct ly above the graph centerline an amount equivalent to half the side reading using
the graph division lines as I mil each (the scale can be 2, 3, 5, 10. or 20 mils as long as
the machine centerline fits on the g raph).
If the side reading (N, S, E, W) on the either shaft was positive ... stan at the
intersection of the graph centerline and the dial indicator position line and mark a point
directly below the chan centerline an amount equivalent to half the side reading.
Position the machinery centerlincs to go through the marked points on the dial
indicator position line for each shaft and the point where the graph centerli ne and the
alignment bracket position lines intersect.

44
 Shaft Alignment Graphing Techniques

Sample graphs in the SIDE and TOP views

motor
0

·0+50
-2

south

45
Basic Shaft Alignmenl Workbook

Combining the SIDE and TOP VIEWS

f yjew
sipe
u

46
 Shaft Alignment Graphing Techniques

Alter the graph set up for assymetric

bracket and indicator positions
The ideal bracket and indicator placement has the indicators
in the same plane as the bracket clamping position.

-
---
-
-
-
--
-
-
-

!
alignment bracket I di:ll indicator l o;:otior~<

An assymetric bracket and indicator set up requires that you

position the centerlines based on the points from where you
are clamped on one shaft (where the bracket is attached) to
the point where the dial indicators are taking their
measurements on the other shaft.

I I : :

.
I I
I I
I I

: ~-r ~
--·
47
 Shaft Align men! Graphing Techniques

Shaft Alignment Graphing

Techniques

Face-Peripheral Graphing Method

49
Basic Shaft Alignment Workbook

Setting up the graph

Measure the distances between the inboard and
outboard feet on both machines, the distance from the
inboard feet to the points where the dial indicator
stem(s) are touching the shaft, and the distance from the
dial indicator(s) to the bracket mounting position.

motor
\ pump

~ ..._ I" per division

Accurately scale the distances measured

above onto the graph paper.
*,Note: The scale can be 1", 2", 3", 10" per division. Select
the smallest scale factor !hal fils the entire drive train onto
the graph paper.

50
 Shaft Al ignment Graphing Techniques

The 'T' Bar Overlay

To graph the Face-Peripheral dial indicator method, you

need to have a clear piece of plastic with a T' inked onto the
plastic similar to what is shown below.
The T' bar overlay represents the shaft where the dial
indicators are capturi ng readings. ln the examples shown here,
the T' bar represents the pump shaft since the dial indicators are
taking readi ngs on the pump with the bracket attached to the
motor. In this arrangement, you are trying to 'see' where the
pump shaft is with respect to a point on the motor shaft
centerline.
Remember where the dial indicators are taking thei.r
readings. There would be nothing wrong with mounting the
bracket to the pump shaft and capturing readings on the motor
shaft. If the bracket was attached to the pump shaft, then the 'T
bar would have to represent the motor shaft position.

T bar face - peripheral overlay line

(on transparent plastic)

Scale the face reading diameter onto the 'T'

* make sure you use the same scale factor as you used to lay
out the overall machinery dimensions on the graph paper

51
Basic Shaft Alignment W orkbook

Motor and Pump Example

in the Side View

fT\
i pump shalt I

~
~
motor I"~ pump
: .,.,_,_.
I: ,.....,_
- · -......

52
 Shaft Alignment Graphing Techniques

Face-PeriJ?heral
Graphtng
Example 'front' side face readings
taken on a s· diameter
+36

up

53
 Shaft Alignment Graphing Techniques

Shaft Alignment Graphing

Techniques

Shaft to Coupling Spool Graphing

Method

55
B;1~k Shaft A lignme nt Workbook

Setting up the graph for Shaft to

Coupling Spool Modeling
Measure the distances between the inboard and
outboard feet on both machines, the distance from the
inboard feet to the points where the fl exing points are
located at both e nds of the coupling spool I jackshaft,
the distance from where the flex ing points are to where
the dia l indicator ste ms are touching the coupli ng spool,
and the distance between the dial indicators.

~- L J

1·· per division

Accurately scale the distances measu red above onto the graph paper.
*Note: The scale can be I". 2". 3". I 0" per division. Select the smallest scale factor
that fits the entire d rive train o ntn the graph pape r.

56
 Shaft Alignment Graphing Techniques

motor to spool gear to spool

Shaft to Coupling
Spool Graphing
Example
+12~-56 +32~-12
\...Vnote : readings have ~
_44 been compensated for +20
bracket sa

up
+-
+-
I+ fftt
it

~.

t;.
·:...""'
lttl rt-
Iii±
lml

t. t ·!i,·_. ~ t--
east C't il il
~
It
f..
g

t-±+

rt.
57
 Positioning the Machinery

Positioning the Machinery

• shaft alignment in a 3 dimensional world

• how far can the machines be moved laterall y?
• controlling your lateral moves
• how to check for excessive static piping stresses

59
Basic Shaft Alignmenl Workbook

Shaft alignment in a 3 dimensional world

ax ial position

horizontal position

vertical position

60
 Positioning the M achinery

How far can the machines be moved laterally?

Setting the machine cases so they are in the center of their travel.

First ...
push the machine cases
to one side until the
bolts bottom out against
the holes. Set up dial
indicators at the sides of
the feet and :zero the
indicators.

bolt shank

next ...
push the machine
cases the opposite way
until the bolts bottom
out in the holes again.
Make a note of the
amount of movement
on each of the
indicators but don't
move them!

®. I
.

finally ...
push the machine cases
halfway back watching
the indicators to see
how much you've
moved.

61
Basic Shaft A lignment Workbook

Controlling your lateral moves

Machinery has a great tendency to misbehave when
moving sideways. Quite often machine cases will translate
or slide straight sideways rather than pivot at one end. For
instance, if you are not watching what happens to the
inboard end while you are moving the outboard end, a shift
at the inboard end may have occurred that you didn't
notice.

Here are some suggestions to help minimize potential

problems ...
• have indicators mounted to monitor any movement at
the inboard and outboard ends of the machinery
• zero the indicators prior to loosening the foot bolts
particularly with machinery that has piping or ductwork
attached to it (if you see more than 2 mils of movement
sideways on the machine case after loosening the bolts, you
may have an uncorrected 'soft foot' problem or excessive
static piping stress)
• use jackscrews wherever possible not only to move the
machinery but also to hold one end in place when trying to
position the other end
• if you don't have jackscrews ... use one of the foot bolts
as a 'pivot' point , move the outboard end frrst, then use an
alignment bracket and dial indicator to assist in positioning
the inboard end (see the illustration on 'Pivoting at the
Inboard and Outboard Ends')

~ lateral control with a 20

pound sledge hamme r.
\

62
 Positioning the Machinery

'Pivoting' at the outboard and

inboard ends of the machinery

Fi~t. IOOSC-n all buc one of the lnbollrd

boltJ and 1novc the outboard end the
move amount you dcc;idc<J upon

Nut. tighten one of the outboard bolts, loe»en the inboard

boh u*'CS as a 'pivot' point, mount the braeket and indk:atOr
on10 one of t.he shafts. rowe the bncket and indkal<W ~er
oo one si6<. wo !he indicaw<. ,.,.... 10 ohe Olher sicle and
molte a nooe of ohe r<adtiiJ
~e

63
Basic Shaft Alignment Workbook

How to check for excessive

static piping stresses
Attach brac kets or c lamps to one shaft and mount
dial indicators in the vertical and horizontal
position against the other shaft. Zero the indicators
after the alignment is completed and monitor for
changes as you begin to attach the piping.

M ovement should be less th an 2 mi ls (0.002.') in any direction.

64