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  • All About Shaft Alignment

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    Mahmoud Abd El Lateef
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    The document discusses the importance of proper shaft alignment for rotating machinery. It states that 50% of rotating machinery will need repairs within 16 months due to misalignment. Proper alignment reduces forces on bearings and other components, minimizing wear and increasing lifespan. It provides examples showing how alignment can save over $1,700 per year on a 100HP extruder and $370 per year on a 20HP pump in reduced energy costs alone.

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    The document discusses the importance of proper shaft alignment for rotating machinery. It states that 50% of rotating machinery will need repairs within 16 months due to misalignment. Proper alignment reduces forces on bearings and other components, minimizing wear and increasing lifespan. It provides examples showing how alignment can save over $1,700 per year on a 100HP extruder and $370 per year on a 20HP pump in reduced energy costs alone.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    55 views3 pages

    All About Shaft Alignment

    Uploaded by

    Mahmoud Abd El Lateef
    The document discusses the importance of proper shaft alignment for rotating machinery. It states that 50% of rotating machinery will need repairs within 16 months due to misalignment. Proper alignment reduces forces on bearings and other components, minimizing wear and increasing lifespan. It provides examples showing how alignment can save over $1,700 per year on a 100HP extruder and $370 per year on a 20HP pump in reduced energy costs alone.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 3

    All About Shaft Alignment

    Misaligned Rotating Machinery Has Caused And Will Continue To Cause Tremendous Financial Loss To Every Industry World Wide Lost production Prematurely damaged machinery Excessive energy consumption

    Statistically, Within A 100 Mile Radius Of Any Location:


    50% of all rotating machinery drives are excessively misaligned and will probably need to be shutdown and repaired within the next 16 months The other 50% will probably run uneventfully with little or no maintenance for the next 80 months

    Objective Of Shaft Alignment Is To Increase The Operating Lifespan Of Rotating Machinery


    The most common components likely to fail due to misalignment are: Bearings Seals Couplings Shafts

    What Do I Need To Know To Correctly Align Rotating Machinery?


    Where is the machine at off-line? What position will the machinery move to when operating? What are appropriate off-line alignment specifications to maintain correct alignment tolerances during operating conditions?

    Only one out of every five alignment technicians realizes that machinery moves from off-line to operating conditions

    IN-PLANT SERVICES, INC GREENVILLE, SC 864.575.9987 www.inplantservices.com cmorton62@prtnet.com

    PDF created with pdfFactory trial version www.pdffactory.com

    Benifits Of Accurate Alignment


    Reduce forces on the bearings to insure longer bearing life Minimize wear in the coupling components Minimize the amount of shaft bending Eliminate the possibility of shaft failure from cyclic fatigue Reduce power consumption (documented 2 to 17 %) Maintain proper internal rotor clearances Lower vibration levels in machine casings, bearing housings and rotors

    Economics Of Accurate Alignment


    To calculate the energy savings of a 100 hp extruder drive that runs continuously for one year KW/hr = horse power rating / efficiency rating x .746 KW/hr = 100 / .92 x .746 = 81.1 $ savings / yr = KW/hr x operation hrs x electrical rate x percent improvement $ savings / yr = 81.1 x 8400 x .05 x .05 $ savings / yr = $1,703.10 Even at a low percentage of return ( 5% ) the energy savings alone will repay the cost of the average alignment in less than 3 months To calculate the energy savings of a 20 hp driven pump that runs continuously for one year KW/hr = horse power rating / efficiency rating x .746 KW/hr = 20 / .85 x .746 = 17.6 $ savings / yr = KW/hr x operation hrs x electrical rate x percent improvement $ savings / yr = 17.6 x 8400 x .05 x .05 $ savings / yr = $369.60 Even for a small hp motor the yearly energy savings at a low percentage of return ( 5% ) will repay the cost of the average alignment in less than 1 year. Bibliography John Piotrowski, SHAFT ALIGNMENT HANDBOOK Marcel Dekker Inc.

    IN-PLANT SERVICES, INC GREENVILLE, SC 864.575.9987 www.inplantservices.com cmorton62@prtnet.com

    PDF created with pdfFactory trial version www.pdffactory.com

    Shaft Misalignment
    Measured Shaft Alignment Data, Pump (mils) horz vert offset angle offset angle 78.5 5.5/1 4.0 3.1/1 right left high down

    Suggested Shaft Alignment Tolerances (mils) offset 2.0 angle .3/1 vert offset 2.0 angle .3/1 ThermaGram of pump and motor minutes after start-up, lost energy via heat generated at the coupling because of shaft misalignment, misalignment verified by vibration analysis and measurement horz

    *>80.0F 80.0 75.0 70.0 65.0 60.0 55.0 50.0 *<50.0F

    74.0

    76.3

    67.7

    IN-PLANT SERVICES, INC GREENVILLE, SC 864.575.9987 www.inplantservices.com cmorton62@prtnet.com

    PDF created with pdfFactory trial version www.pdffactory.com

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