Training Module ALIGNMENT

WHAT IS ALIGNMENT?

When machine shafts are in their own geometrical

position, they are known in alignment.
Two parallel shafts are called in alignment in case of
spur and helical gearing, belt drive, etc. For bevel
gear, the shaft should intersect to each other. For
coupling drive, the shaft axes should be collinear.

ALIGNMENT OF COUPLING:
When axes of two shafts which to be coupled each
other to transmit motion and power, are collinear is
known in alignment.

ILL EFFECTS OF MISALIGNMENT: Following may

be the ill effect of misalignment:
(a) Too much noise and vibration
(b) Too much heat generation
(c) Too much power consumption
(d) More wear and tear of coupling components and
bearing
(e) Frequent damage and failure of bearing and
gears

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(f) Chances of failing lubrication of bearings and

gears
(g) Chances of getting loose the coupling and
foundation bolts
(h) Frequent failure of gland packing and oil seal
(i) Value of misalignment will go on increasing
(j) Unbalancing effect
(k) Much more stress concentration and fatigue
failure
(l) More down time and maintenance cost
(m)Poor job quality
REASONS OF MISALIGNMENT: Following may be
the reasons of misalignment of coupling:
(a) Inaccuracy in alignment in initial condition
(b) High torque transmitted through the coupling
(c) Frequent shock load on the machine
(d) Too high coupling speed
(e) Unequal temperature rise in two shafts
(f) Foundation bolts and coupling bolts are not
tightened properly
(g) Smaller sized foundation
(h) Setting, seasoning or spinning the foundation
(i) Undersized foundation bolts and coupling bolts
(j) Smaller sized coupling used
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(k) Missing coupling bolts

(l) General bolts used instead of machine bolts
(m)Unbalanced rotating components
(n) Improper mounting of bearings on shaft and
housing
(o) Wear of bearing
(p) Soft foot of machine bed
(q) More nos. of packing used
(r) Bend shaft
TYPES OF COUPLING
MISALIGNMENT:
There are the three types:
(a) Parallel or rectilinear misalignment: when the
axes of two shafts are parallel to each other, but not
collinear, is called parallel misalignment.

(b) Angular misalignment: When the axes of two

shafts are intersecting to each other at some angle,
is known as angular misalignment.

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(c) Combined misalignment: when the axes of two

shafts are neither parallel nor intersecting to each
other, is known as combined misalignment

INSTRUMENTS, TOOLS AND OTHER

ACCESSORIES USED FOR ALIGNING:

PROCEDURE FOR ALIGNING COUPLINGS:

Before aligning couplings mounted on two shafts,
following pre-checks are required:

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(a) The diameters of both the coupling should be

measured. The both diameters should be exactly the
same.

(b) The concentricity of coupling on shaft:

The axes of coupling and shaft should be collinear.

A dial test indicator plunger is placed with preload
and dial zero setting on the coupling periphery with
its stand on some firm base. Coupling is rotated
individually to know the deviation in DTI. If there is
no deviation, the coupling is concentric on shaft,
otherwise not. If there is some small deviation, it
should be noted at four 90o position of coupling. It
helps us at the time checking parallel misalignment.
Following may be the reasons for eccentricity of
coupling:
- Improper machining of coupling hole in the center.

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- Improper way of mounting coupling on shaft

- Too much clearance between hole and shaft
- Improper size of key fitted between them
- Bend shaft

(c) Perpendicularity of coupling face on shaft axis:

The face of coupling should be mounted exactly at
right angle on shaft axis. It is again checked with DTI
method. DTI plunger is faced on coupling face with
preload and zero dial setting. Coupling is rotated.
Any deviation in reading shows inaccuracy in
perpendicularity of coupling on shaft. If the value is
mall, it is noted at four right angled positions. It helps
while checking angular misalignment. Following may
be the reasons of angular misalignment:
- Improper machining of coupling hole in the center.
- Improper way of mounting coupling on shaft
- Too much clearance between hole and shaft
- Improper size of key fitted between them
- Bend shaft

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(d) Soft foot of the machine bed: it is checked by

inserting thin leaf of feeler gauge underside of each
foundation bolt positions. The foundation bolts
should not be in tighten position while checking the
soft foot.

(e) Identifying Stationary machine (SM) and Machine

to bee shimmed (MTBS):
Normally the machine part which can be lifted or
shifted from its position easily, is selected as MTBS.
SM position of machine parts must have some initial
height from MTBS.

(f) Leveling of shaft: It is sometimes becomes more

useful while aligning, specially in case of long line
shaft.

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(g) Types of coupling used.

(h) Scratches, rust and corrosion, dents, etc. on

coupling periphery and face.
Mark coupling periphery at four points at 90o
apart. Check all foundation bolts are fully tight.
Check angular misalignment in vertical plane
first. For checking angular misalignment in vertical
plane, measure top and bottom gaps between
coupling with taper gauge. If taper gauge is not
available, use feeler gauge.
Measure distances of front foot bolt and rare foot
bolt position of MTBS from coupling end.
Calculate the thickness of shims from the
following formula

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x = {(TG – BG)/D}L1 & y = {(TG – BG)/D}L2

Where, x = Thickness of shims under front foot bolt
position
y = Thickness of shims under rare foot bolt position
TG = Top gap between coupling
BG = Bottom gap between coupling
D = Diameter of coupling
L1 = Distance of front foot bolt position from coupling
face
L2 = Distance of rare foot bolt position from coupling
face
Insert (if x & y are positive) or remove (if x & y
are negative) shims equal to calculated thickness (x
and y) under respective bolt positions after lifting
MTBS with suitable device. Tighten all the bolts.
Measure top and bottom gap again. Add shims
equal to soft foot if there is any amount found in pre-
checks.
Measure front and back gap between the
coupling with taper gauge or feeler gauge and shift
MTBS to remove angular misalignment in horizontal
plane.
Check parallel misalignment in vertical plane.
Place a straight edge on the top of both the coupling
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and measure the gap with feeler gauge if any found

between the straight edge and coupling. Insert or
remove shims from all four bolt position to remove
parallel misalignment from vertical plane.
Check the parallel misalignment in horizontal
plan with straight edge and make it correct by
shifting MTBS.
Mount a DTI base on SM coupling with suitable
fixture and DTI plunger on the periphery of MTBS
coupling top with preload and zero dial setting to
remove parallel misalignment from vertical plane
further.

Rotate SM shaft till the DTI comes to down most

position. Check he readings in DTI.
Insert (for positive value) or remove (for negative
value) the shims equal to half the reading of dial test
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indicator under all four bolt positions. Check the

readings again on top and bottom.
Check the reading of DTI on front and back side
of the coupling and shift the MTBS parallel to axis to
remove angular misalignment in horizontal plane.
Do the whole process again, still there is some
misalignment between couplings.
LIMITATIONS:

Both coupling diameter may not be the same.

Non-availability of taper gauge and unskilled way
of using feeler gauge to measure coupling gap.
Peripheral surface of coupling is not free from
rust and corrosion, scratch, etc.
Eccentric coupling on shaft.
Non-perpendicular coupling face on shaft.
Too much gap between coupling face like fluid
coupling.
Sagging of DTI fixture.
Inadequate space for rotating DTI fixture 360o
around the coupling.
Following may be the way for aligning coupling
under these situations:

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If coupling diameters are not the equal, use DTI to

check and correct parallel misalignment. If taper
gauge is not available, use feeler gauge to know the
gap with a depth of maximum 10 mm. Gap can be
checked also by using DTI fixing the plunger on the
back side of the face of the coupling and base on
other side shaft. Too much gap can be checked with
the same method. In case of eccentric and non-
perpendicular coupling and corroded coupling,
couple both the coupling with a loose bolt an do the
alignment as explained earlier. Sagging of DTI
fixture can be checked separately and the value is
being taken care while calculating the thickness of
shims for removing misalignment. Algebraic sum of
the readings taken at 3 ‘O’ clock and 9 ‘O’ clock of
DTI gives the value for 6 ‘O’ clock. It avoids rotating
of DTI fixture 360o around the coupling.

SAFETY PRECAUTIONS:
Must check the capabilities of all tools and
tackles which will be used for lifting purpose.
Shims and liners must not have sharp edges.

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Shims and liners should be made of adequate

dimensions.
While lifting and inserting shims, beware of
catching fingers between bed and foundation.
Proper sized spanners should be used while
tightening the bolts. Never use spanners with pipes
for increasing the length.
Worn-out spanners, screw spanners and pipe
spanners must not be used for tightening bolts.
Never keep straight edge on rough corroded and
hot surface.
Never rotate DTI plunger on rough surface of
couplings.
Use minimum numbers of liners or shims
underside of machine bed.
Use proper PPE while working.

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