AYTB TECHNICAL TRAINING MANUAL - MACHINERY ALIGNMENT
Alignment- Brief notes
(please read the detailed notes given to your supervisor)
Two primary reason for machinery vibration are unbalance of the rotor and coupling misalignment. The
simple rule for enhancing rotating equipment availability is “Keep it balanced, keep it straight”. Let us
learn how to keep it straight.
During normal operation, the shaft alignment can get affected due to the following reasons:
thermal expansion of supports
stresses from pipes
deformation of structures
modifications in the sag of the rotor with the rise in temperature.
Inadequate correction prior to start up.
In some cases, the movements of shafts can be predicted and accounted during the process of
alignment. However this is not always possible in all cases. In such a case it is then recommended that
the machines be brought to their nearest operating conditions like the required pressure and temperature
in pipes and casings of pumps, compressors, turbines or any other.
1.a.1 Alignment Conventions using a Dial Gauge
The conventions followed are as below:
When the compression spring, dial pointer is pressed inwards the clock needle moves clock-wise
indicating a positive reading. When the pointer moves outwards the clock needle moves counter-
clockwise indicating a negative reading.
Dial gauges are available in metric or US system. In US system Dial indicators usually have either a
1" or 2" range and are calibrated in increments of .001". A smaller dial reads each revolution of the
larger dial in increments of 0.100".
In Metric system, one division is 0.01mm. One complete revolution of the needle corresponds to
plunger movement of 1.0mm. The smaller dial in this case reads each revolution of the larger dial in
increments of 0.100mm.
The dial gauge is normally clamped to a bracket and the dial pointer is placed on the shaft end or
coupling hub. The dial pointer is pressed to somewhere in its mid-range. This is done in order that
both the positive or negative readings are not missed due to end-of-travel of the pointer. At this mid
position of pointer, the dial clock scale can be turned to match the zero with the clock needle.
It is recommended to jog the pointer from the top to ensure that it is not stuck and repeatable readings
are obtained.
AYTB TECHNICAL TRAINING MANUAL - MACHINERY ALIGNMENT
Another conventional followed for alignment readings in horizontal plane is as shown below in the
figure.
The view is taken from behind the Fixed Equipment looking at the Movable Equipment OR Machine
to be shimmed (MTBS). Left and right readings on the dial gauge are recorded accordingly.
RIGHT
VIEW
LEFT
Set up on the shaft must be simple and rigid. Magnetic clamps must be avoided, as their attachment
is not reliable.
1.b Types of Misalignment
1.b.1 Angularity (Parallelism)
Angularity is the difference between the values on the comparator for ½ a revolution. For a
given angular misalignment, angularity depends on the diameter subscribed by the dial
gauge. It can be observed that as d1 increases to d2, p1 increases in the same ratio to p2.
Angle of misalignment = = tan-1 (p1/d1) = tan-1 (p2/d2)
Where ,
p1, p2 = dial gauge reading when rotated by 180 degrees.
d1, d2 = diameter subscribed by the dial gauge
1.b.2 Radial Misalignment (Offset)\
When the dial gauge measures concentricity, the offset as indicated in the figure above
becomes its radius of rotation of the dial gauge.
The dial gauge readings would however indicate the diameter and hence should be reduced
by half to obtain the true offset reading.
Offset = (Dial Gauge reading / 2)
AYTB TECHNICAL TRAINING MANUAL - MACHINERY ALIGNMENT
However as mentioned, in practice misaligned observed on machines is a combination of
both and is shown in the figure below.
1.c Alignment Methods
Two types of dial alignment methods adopted for aligning rotating equipments are
Two Dial Method
Reverse Dial Method
1.c.1 Two Dial Method of Alignment ( not included in this hand out.
Please read the detailed alignment notes given to Supervisor)
1.c.2 Reverse Dial Method of Alignment
The setup for the reverse dial method is as shown in the figure below. Reverse dial method is
generally employed on couplings that have spacers between them.
This method provides many advantages and these are as listed below:
Accuracy is not affected by axial movement of shafts
As both the shafts are rotated together, run outs on coupling hubs are not measured
Geometric accuracy is better than two dial method
Couplings need not be opened to measure the misalignment
Sag and thermal rise corrections can be incorporated
We now consider the above setup to obtain shim corrections by the reverse dial method.
The following convention is used:
Dial B with pointer on the fixed machine (not shown) is in plane B
Dial A with pointer on the motor (MTBS) is in plane A
Motor foot closer to Dial A is the inboard foot and named as IB foot or Front Foot (FF). The
outboard foot of the motor is called as OB foot or Rear Foot (RF)
Distance between plane A and B = X = 14 inches
Distance between plane A and FF = Y = 12 inches
AYTB TECHNICAL TRAINING MANUAL - MACHINERY ALIGNMENT
Distance between FF and RF = Z = 26 inches
On checking for sag the following was observed
The dial with the clamp is set as shown above in top position. The pipe with the clamp is then
rotated by 180 degrees. Due to the sag of the clamp, the dial pointer moves outwards
indicating a negative figure of – 6 mils.
The dial gauges A and B are then setup on the machine as shown in the figure. Dial A has its
pointer on the motor coupling hub and is in top position. The pointer of Dial B is on the fixed
machine and is in bottom position.
The shafts are then turned through one complete revolution and readings of the dial gauges
are recorded at every quadrant.
These are as shown below:
The above readings have been influenced by sag. The sag check has indicated a dial reading
of - 6mils. This was obtained after rotating the dial from the top to bottom (TB) positions.
The dial gauge A too has moved from a TB positions. So it implies that is showing 6 mils
more than the value due to misalignment. It should thus be subtracted to get the correct data.
Reading minus the Sag
The Dial A readings are - Top: 0 and Bottom : +4. After sag correction the readings to be
considered is Top : 0, Bottom: +4 – (-6) = +10 .
The horizontal readings as mention are not affected by sag.
AYTB TECHNICAL TRAINING MANUAL - MACHINERY ALIGNMENT
The Dial A is on the Motor (MTBS) shaft. As the bottom reading is positive, it indicates that
at the vertical plane of dial A pointer (say plane A), the measured object (motor coupling) is
in lower position.
The readings of Dial B also need to be corrected for sag. In this case the dial begins its
journey from bottom and finishes at top. Thus technicians normally keep the dial reading as
zero at the bottom position.
A convention is followed for easier calculation where the top readings are reduced to zero
(0). Subtract +12 mils from top and bottom to obtain this. Thus the reading at “B” plane
becomes 0 at Top and -12 at the bottom.
To correction of Sag repeat the above procedure of subtracting the sag check reading (-6 mils
in this case) from the bottom reading.
The sag corrected readings of Dial B would be: Top : 0, Bottom : -12-(-6)= -6
As a convention for vertical dial correction for the horizontal correction the left plane while
viewing the Movable machine (MTBS) from the fixed machine is taken as the reference.
Hence the left place reference reading to be made zero (0). Hence the final readings will be
as shown below.
Horizontal Correction
The Alignment in the Horizontal plane has to be adjusted as Step-1. The dial readings are the
total indicated reading (TIR) and hence should be halved while plotting. The convention is
to view the Moving machine (motor) from the Fixed machine (pump).
The sign conventions are shown below.
AYTB TECHNICAL TRAINING MANUAL - MACHINERY ALIGNMENT
The Net result from the graph is that the motor at Front Foot (FF) should be moved 7 mils to
the right and at the Rear Foot (RF) should be moved 9 mills to the right. Foundation bolts are
loosened and the jack bots are used to adjust the position. Fix a dial test indicator at the base
to ensure the accuracy of the movement. After final adjustment the jack bolts are locked in
position.
Vertical Correction :-
As the pointer of Dial B is on the fixed machine and while moving from the bottom to top the
pointer gets pressed inwards to give a positive reading. This implies that in the vertical plane
of Dial B pointer (say plane B), the object (pump) is higher.
Thus the dial readings to be considered for calculations are –
Dial A Top : 0 Bottom : +10 object (motor) in plane : Lower
Dial B Top : 0 Bottom : -6 object (pump) in plane : Higher
As the Total Indicated dial gauge Readings (TIR) are double of the misaligned value these
need to be halved.
Radial Offset at plane A is +5 mils
Radial Offset at plane B is -3 mils
While plotting the graph this convention ( below) to be remembered. At A location in the
graph 5 divisions are marked towards the + ive signage ( below the reference line) . At “B”
location on the 3 divisions are marked towards the
–ive signage (below the reference line).
AYTB TECHNICAL TRAINING MANUAL - MACHINERY ALIGNMENT
The result obtained from the graphical solutions are shown above. 6mils shims to be added at
the Front foot (FF) and 10 mils shims to be added at the Rear foot (RF) of the motor.
Analytical method
There is an analytical method that provides formulae to compute the shims when using the
reverse dial alignment method.
Te formulae are as follows:
Shims at Front Feet = ((A + B) / X) * Y + A
Shims at Rear Feet = ((A + B) / X) * (Y+Z) + A
AYTB TECHNICAL TRAINING MANUAL - MACHINERY ALIGNMENT
Where
A – The radial offset of the dial with pointer on MTBS
B - The radial offset of the dial with pointer on FM
X – Distance between the two dial pointers
Y – Distance between Dial A and Front Feet
Z – Distance between Front Feet and Rear Feet
In our earlier example the values were as below for the horizontal correction
A = -0.006” B = +0.005” X= 14” Y= 12” Z = 26 “
Substituting this values in the formula we get
Horizontal movement at Front foot = -0.0068”
Horizontal movement at Rear foot = -0.0087”
Note :- Here + ive sign means move to left and –ive sign means move to right.
Similarly Let us now look at the Vertical movement
A = +0.005” B = -0.003” X= 14” Y= 12” Z = 26 “
Substituting this values in the formula we get
Vertical movement at Front foot = +0.0067”
Vertical movement at Rear foot = +0.010”
Note :- Here + ive sign means add shims and –ive sign means remove shims.
The computed movements matches with the earlier graphical result.
Compensation for Thermal growth -
The machine pedestal is assumed to be undergoing a uni-directional thermal expansion and
the formula for linear expansion is used to calculate this increase in length.
dL = L () (dT) Where dL = thermal expansion L = height centerline to base of machine
= coefficient of thermal expansion of material
dT = change in temp from ambient.
The thumb rule states:-
There is a rise of 1 mm for 1 m of length for a 100 deg. C rise in temperature.
OR
There is a rise of 1 mil for 1 inch of length for a 100 deg. C rise in temperature.
Increase the result by 20 %.
In the above example, the rise in temperature is 100 C. Thus 0.5 m length will raise by 0.5
mm. Now, increase it by 20 %, so the answer is 0.6 mm.
In inches let us approximate the length to 20 inches, so for 100 deg. C raise it will be 20 mils.
Now increase it by 20%, so it will be 24 mils.
Once the growth is known it is adjusted against shim correction.
AYTB TECHNICAL TRAINING MANUAL - MACHINERY ALIGNMENT
If the alignment results indicate that the feet have to be raised by adding shims of 0.85 mm
and we see that the thermal growth will be 0.6 mm, then shims of only 0.25 mm should be
added. The rest of rise will occur by expansion.
If the alignment results indicate that shims of 0.4 mm need to be added in the above case,
then infact, shims of 0.2 mm should be removed.
1.d Things we care before we start the machinery alignment –
1.d.1 Safety
Safety is our first and foremost concern when working around machinery. All equipment
should be locked and tagged out before any work is performed on it. The machine should be
given ample time to cool. The surrounding area should be free of obstructions and debris. Hot
piping near the area should be covered.
1.d.2 Check Eccentricity (Runout) -
The alignment of shafts is carried out by using reference points situated on the shaft ends,
coupling hubs or any other part attached to the latter.
The machining imperfections can cause each of the shaft ends to cam shaped or eccentric.
To check this, a dial gauge is fixed to one shaft end A with the pointer on the other shaft end
B. When the shaft end A with the dial base is rotated the reading on the dial pointer indicates
the eccentricity of the shaft end B.
1.d.2 Remove Base plate defects (Soft foot) -
It is essential that the feet of the machines rest simultaneously on the base plate so as to
prevent any deformation of the body or the breaking of the leg. Likewise, if all four-support
points are not on the same plane, the position of the axes will depend on the order in which
the hold-down bolts are tightened. The dial pointer should be placed in the vertical direction.
The machine is tightly bolted to the base. Now each bolt is loosened one at a time and the
upspring is noted on the dial gauge.
Any dial reading, which is prominently higher than the others, is an indicator of soft foot at
that location.
The soft foot is easily corrected by placing a shim of appropriate thickness under the foot,
which has a more than required gap.
1.d.3 Measure Axial position of machines & adjust DBSE-
AYTB TECHNICAL TRAINING MANUAL - MACHINERY ALIGNMENT
The axial position of the shaft ends is referred as DBSE (distance between shaft ends).
Normally most of the couplings allow for a large tolerance in the axial position and so it is
not an important check.
However for couplings like disc couplings an error in the axial position places the discs
under stress and decreases their life. It may also generate axial thrusts, which ultimately add
load to the machines thrust bearings.
It is therefore necessary that this aspect be taken into consideration, especially when the
machines are in high temperature service.
If X is the recommended DBSE for the coupling, the X+0.5 mm is kept for machines
conveying a product in the temperature range of 100 to 200 deg C.
It is X+1 mm when the conveyed product temperature is between 200 to 250 degrees C
1.d.4 Check and account for Bracket check (Sag)
There is a tendency for such brackets to sag. This sag can alter the dial gauge readings
leading to misinterpretation and errors. For bracket lengths greater than 25 to 30 cms, it is
essential to provide additional stiffness to minimize sag.
Thus it is necessary to perform a sag check of the bracket. Sag check is essential only for
aligning horizontal machines as the sag is caused by gravity on the weight of the bracket.
To do a rim sag check, mount the bracket on a stiff pipe, zero at the indicator at mid range in
the top position, and roll the pipe from top to bottom on saw horses, and note the bottom
reading. The total sag is twice the bracket sag.
1.f Alignment Tolerances
The following table provides with the residual misalignment values, which can be safely
used for machines. The values are based on the machine’s operating speed. Note :- 1 mil =
0.001 inch = 0.025mm
Excellent Acceptable
OFF SET Angle OFF SET Angle
Speed mil mm/ mils/ (mm/ mils mm/ mils/ (mm/
(RPM) s 100 inch 100)/ 100 inch 100)/
100 dia 100 dia
1250-
3 8 0.5 5 4 10 1 10
2000
2000-
2 5 0.3 3 3 8 0.5 5
3500
3500-
1 3 0.25 3 2 5 0.3 3
7000
> 7000 0.5 2 0.2 2 1 3 0.25 3
