CONSTRUCTION MAINTENANCE

DEPARTMENT
MECHANICAL TECHNICIAN
QUALIFICATION MODULE

ALIGNMENT TRAINING
COURSE
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INTRODUCTION

With any shaft-to-shaft alignment,

it is important to find the axis of
rotation of one shaft relative to the
other to eliminate the effects of
mounting errors on the
measurement.

Properly aligned motors and pumps

will last longer, perform better and use
less electricity. Not only will you
perform motor/pump alignment in
record time, but you will also increase
the life of your motor bearings and
seals, saving you thousands of dollars
annually in reduced maintenance costs.

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OBJECTIVES
IN THIS TRAINING MODULE THE ATTENDANT WILL LEARN :
Types Of Alignment.
Real cost of misalignment.
What causes misalignment?
Coupling gaps, magnetic centers.
Soft foot.
Bar sag, true directions, coupling backlash.
Pre-alignment checks.
Straight edge & feeler gauge method.
Rim & Face method.
Reverse or double dial indicator method.
Graphing.
Alignment tips.

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MAIN MENU
Learning
Objectives

Misalignment
Types

Alignment
Methods

Data Sheets

Flash Cards

RADIAL RUNOUT

The amount of
eccentricity in the
coupling hub.

Shaft run out.

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AXIAL PLAY

The amount of which a

machine shaft can move
along its axis.

How to measure the axial

play?

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FACE RUNOUT

3 PULL

The amount of face

square ness with
shaft axis.

2 ZERO

1 PUSH

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MAGNETIC CENTRE

Motor rotors when

run, shifts to its
centre position, this
is called magnetic
centre.

Before you couple,

the motor rotor has
to be centered.
POWER ON
POWER OFF

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EFFECTS OF MIS-ALIGNMENT
Excessive machinery vibration.
Excessive electrical power consumption.
Premature bearing failure.
Premature failure of gasket, packing and mechanical seals.
Premature coupling parts failure.
Excessive machinery downtime.
Excessive maintenance cost. ( mechanical seal)
Lost production and profits.
Warnings and salary deductions.

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CAUSES OF VIBRATION
Misalignment.
Loose tie down bolts.
Loose coupling bolts.
Unbalance.
Loose fits of machinery parts.
Machinery runs on over load.
Having cavitations.
And other reasons.

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VIBRATION COST
Vibration is a wasted energy spent in the form of watts.
Vibration shortens machinery components life.
Machinery components examples are: Bearings, seals and couplings.

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VIBRATION ENERGY COST

Vibration is a wasted energy
spent in the form of watts.

300 hp
150 hp

10%

20%

440 V X 1 amp X PF (1) = 440 WATTS.

70%

440 / 1000 = 0.44 Kw. Hr

0.44 Kw. Hr X 24 hr + 10.56 Kw. hr/day
10.56 Kw. hr/day X 365=3854.4 Kw. hr/year

2 hp
Plant Machinery Distribution

3854.4 X 0.020 KD = 77 KD/year/Machine

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BEARING FAILURE
Less than 10% of the machinery
bearings reach their design life.

10 %
40 %

50% of all machinery bearing

failure is because of
misalignment.
40% of bearing failures is
because of unbalance.

50 %

BEARING FAILURE BARREL

10% bearing failures are for

other reasons.
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40% OF THE BEARING FAILURES

DUE TO UN-BALANCE, HOW?

X
B

Damaged coupling bolts.

Damaged coupling keys.

Damaged coupling hub.
Dirt and worn parts.

Tolerance standards.
Improper removing and fixing
of coupling hubs on the shaft.

X = (A+B)/2
X : KEY LENGTH.
A : SHAFT KEYWAY
B : COUPLING HUP KEYWAY

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10% OF THE BEARING FAILURES

10% of the bearing failures due to other reasons.
Tie down bolts torque.

Eccentricity.
Bad mounting.

Oil seal failure.

Oil dirty, oil not changed for long and improper oil grade used.
And many other reasons.

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SEAL FAILURES

30%
30% of the mechanical seal failures
are due to misalignment and
vibration.

25 %
ASSEMBLY
ERRORS

MISALIGNMENT
VIBRATION

27 %
OPERATION

10 %
OTHER

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MIS-ALIGNMENT COST SUMMARY

MIS-ALIGNMENT

VIBRATION

HIGHER MAINTENANCE
COST.
HIGHER PRODUCTION COST.
HIGHER POWER
CONSUMPTION.
HIGHER LOSES IN PROFIT.

BEARING, SEALS,
COUPLING..FAILURES.

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TYPES OF MIS-ALIGNMENTS
Axial misalignment.

Parallel misalignment.

PRALLEL
Angular misalignment.

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ANGULAR

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TYPES OF MIS-ALIGNMENTS
Offset Misalignment:
( Sometimes referred as Parallel
Misalignment) is the distance
between the shaft centers of
rotation measured at the plane of
power transmission from the
driving unit to the driven unit. This
is typically measured at the
coupling centre. The units for this
measurement are Mils (Where 1 Mil
= 0.001)

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TYPES OF MIS-ALIGNMENTS
Angular Misalignment:
( Sometimes referred as gap or face), is
actually the difference in the slope of one
shaft, usually the moveable machine, as
compared to slope of the shaft of the other
machine, usually the stationary machine. The
units for this measurement are comparable
to the measurement of the slope of a roof,
Rise/Run. In this case the rise is measured in
Mils (1 Mil = 0.001). And the run (distance
along the shaft) is measured in inches,
therefore the units of Angular Misalignment
are Mils/1
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CAUSES OF MIS-ALIGNMENT
Thermal growth.

Pipe strain.

Loose tie down bolts.

Base plate not in level.

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THERMAL GROWTH
Is the change in the length of a
particular metal as a result of the
change in temperature of that metal.
Typically, when a metal bar is heated, it
will get longer. These changes can be
very small (0.0005) or they can be very
large, depending on the length of the
piece of metal and its coefficient of
linear expansion. The formula used for
this calculation is often referred to as
the T x L x C formula. T represent the
change in the materials temperature in
degrees Fahrenheit, L represents the
length in inches of the material and C
represents the materials coefficient of
liner expansion.

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TIE DOWN BOLTS

When the machine is removed from
the base plate, tap the tie down
studs. Report it if you find them
loose in the base plate.
Tie down bolts should be torque
correctly.
Too tight or loose bolts might not
secure the machine properly or
damp vibration.

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PIPE STRAIN
While connecting suction and
discharge flanges leave the dial
indicators on the machine and note
the readings of the pipe strain.
Pipe strain should not effect
alignment more than TWO mils.

CAUSES MACHINE FRAME

DISTORTION.

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SOFT FOOT
It settles after a while because of the machine weight.
Base settling causes the machine frame to distorted.
Soft foot has to be corrected before you perform alignment.

UNHAPPY MACHINE
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SOFT FOOT
How to check for soft foot?
1. By dial gauge.
2. By feeler gauge.
3. Laser alignment.

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What is a soft foot?

SOFT FOOT

Angular Soft Foot is a condition that occurs when a gap under a

motor's foot is non-parallel to the mounting base. Because of this
gap, the foot, when tightened, is forced to seat itself to whatever
angle allows it to make total surface contact. As a result of this
seating, stresses are created in the motor's foot that transfers
through the motor leg and into the housing.

How to cure soft foot?

1. By machining.
2. By stepped shimming.

STEPPED
SHIMING

ORIGINAL
SHIMS
{

}
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SPRING FOOT
Too many shims under the foot of the machine can cause spring
foot. ( 3 shims Max. should be used.)

TOO
MANY
SHIMS
{

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BAR SAG
GRAVITY ALWAYS WORKS.
Never under estimate the bar sag.

Always verify by repeating the checks specially when measuring the

bar sag.
Never guess the bar sag. Always do a practical check to find the exact
bar sag reading.

Indicator Bar Sag

Bar Sag (inches)

0.100
0.090
0.080
0.070
0.060
0.050
0.040
0.030
0.020

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0.010
2

10

12

14

16

18 20

Bar Length (inches)

22

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BAR SAG
How to determine a bar sag?

2
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BACKLASH
One of the precision alignment job
waster.
Will add about 0.002 of
misalignment to your job.

To avoid it, count for it.

Before registering the readings,
rotate the coupling always
inwards.

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TIPS

Place the thin shim between the two thicker ones.

Use micrometer to measure each shim thickness to avoid errors due to

two thin shims sticking together.

Never hammer on machine feet. ( Use jack bolts)

Make sure the entire area under the machine feet is clean, this includes
removal of paint or other materials that can give error in the readings.

Use 4 dial indicators when moving horizontally.

Prevent cupped washers.

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TIPS
?

Use 4 dial indicators when

moving horizontally.

Make sure the jacking bolts are

loose before jacking.

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ALIGNMENT METHODS
Straight edge and feeler gauge / taper gauge.
Rim and Face.
Reverse dial indicator.
Laser

With any shaft-to-shaft alignment, it is important to find the axis of rotation

of one shaft relative to the other to eliminate the effects of mounting errors
on the measurement. Traditional methods, like the rim and face method,
attempt to do this but in reality still rely on machined faces and rims for
accuracy. It is easy to see that an error in the flatness of a coupling face or
the concentricity of the rim can affect the measurement.

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STRAIGHT EDGE & FEELER GAUAGE

METHODS
ADVANTAGES
As an initial rough
alignment this method is
fast.

DIS-ADVANTAGES
Generally involves trail &
error way.
Inefficient. ( Time Wasted)
Misalignment readings are
not accurate.

ERROR SCORES
Shaft / coupling run out.
Poor shaft / coupling surface.
Inaccurate measurement techniques.
Incorrect clock position.

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RIM & FACE

ADVANTAGES

DIS-ADVANTAGES

May be used when, only

one shaft can be rotated.

Requires dis-assembly of
the couplings.

Precision alignment us
achievable.

Often involves trial and

error.

Graphical and calculation

is possible.

Time consuming.

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REVERSE DIAL INDICATOR

ADVANTAGES
Precision alignment is
readily available.
Determination of required
moves is efficient.
Require 180 degree
rotation of shaft.

DIS-ADVANTAGES
More difficult to interpret
directions of moves from
indicators readings.
Bar sag if used with long
extension.

No need to worry about

axial play
ERROR SOURCES
Indicator bar sag.
Misreading indicator.
Coupling backlash.

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LASER ALIGNMENT
After 10
years of laser shaft alignment,DIS-ADVANTAGES
it is now an established
ADVANTAGES
fact that lasers are simply faster than indicator based methods.
The
Quick
biggerdetermination
the motor, theof
more timesaved
during alignments. It
Costly.
wasrequired
told by one
customer that they reduced the alignment time on
moves.

usedcan
when
one motor from 2 days to 4 hours! ThisCant
time be
saving
be the
Long spans between
lightdowntime
is too bright.
especially
helpful on critical machinerysun
where
is very
couplings is not a
costly.
problem.
Gives vertical and
horizontal moves at once.

ERROR SOURCES

Laser fixture sag / twist. ( no sag or twist in fixture)

Ambient vibration and ambient temperature.
Coupling backlash.
Laser beam distortion due to stream or dirty prism / lens.
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TIPS ON HOW TO USE MEASURING

TOOLS
FEELER GUAGE
Do not force the gauge in gaps.
Use combination of gauges that fills the gap with only

slight resistance.
when several gauges are combined to fill a gap, it is best
to check the overall thickness with a micrometer.

DIAL INDICATOR
Mount rim dials so that plunger is truly perpendicular to the shaft
centre line.
Check rim readings for mathematical validity.
Mount the face dial so that plunger is truly parallel to the shaft
centre.
Check readings for repeatability.
Eliminate backlash effect on readings.

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PRE-ALIGNMENT CHECKS
Determine alignment method to be used.
Prepare the necessary tools required for the alignment job.
If possible check your magnetic centre and make your markings.

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IMPORTANT DIMENSION
W

Y
A
B

A: DISTANCE BETWEEN DIAL INDICATORS PLANS.

B: DIST. BETWEEN TARGET INDIC. & SIGHT MACHIN INBOARD FEET.
C: DIST. BETWEEN TARGET INDIC. & SIGHT MACH. OUT BOURD FEET.
D: DIST. BETWEEN TARGET INDIC. & TARGET MACH. INBOARD FEET.
E: DIST. BETWEEN TARGET INDIC. & TARGET MACH. OUT BOARD FEET.
W,X,Y,Z : THERMAL GROWTH IN EACH SEPARATE FEET.
TAGET

SIGHT
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EXAMPLE 1.1
: MACH. FEET

17.5
24.5

: TARGET DIAL .
INDICATOR.
: SIGHT DIAL
IDICATOR.

A =17.5
B = 24 .5
C = 53
D = 7.5
E = 30.5

53

7.5
30.5

...DO NOT FORGET

TO MESURE BAR
SAG.
Horizontal scale: 1 Square = 1 inch
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EXAMPLE 1.2
CAL : TARGET COLD
..
ALIGNMENT LINE.
..

CAL : SIGHT COLD

ALIGNMENT LINE.

TIR: TOTAL DIAL

INDICATOR ...
READING.

SAG + 18

SAG + 16.5

TIR
1/2 TIR

6
3

..
....

CAL

TIR + 12
1/2 TIR + 6
+/6

CAL

Horizontal scale: 1 Square = 1 inch

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EXAMPLE 1.3
C: TARGET INDICATOR
MISALIGNMENT
PLOTTED FROM TARGET
CAL.
D: SIGHT INDICATOR
MISALIGNMENT
PLOTTED FROM TARGET
CAL.
MAL :MISALIGNMENT
...
LINE.

SAG + 18

SAG + 16.5

TIR
1/2 TIR

6
3

TIR + 12
1/2 TIR + 6
+/6

CAL

CAL
C

D
MAL

Horizontal scale: 1 Square = 1 inch Vertical scale: 1 Square = 1 mill

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DRAW THE GRAPH

NO THERMAL GROWTH
C: TARGET INDICATOR
MISALIGNMENT
PLOTTED FROM TARGET
CAL.
D: SIGHT INDICATOR
MISALIGNMENT
PLOTTED FROM TARGET
CAL.
E: CORRECTIONS
MESURED IN PLANES OF
THE FEETS.

EXAMPLE 1.4
SAG + 18

SAG + 16.5

TIR
1/2 TIR

6
3

TIR + 12
1/2 TIR + 6
+/6

CAL

CAL
C

+7

CAL : TARGET COLD

..
ALIGNMENT LINE.
..

MAL

+12

CAL : SIGHT COLD

ALIGNMENT LINE.

MAL :MISALIGNMENT
...
LINE.
TIR: TOTAL DIAL
..
INDICATOR ...
....
READING.

Horizontal scale: 1 Square = 1 inch Vertical scale: 1 Square = 1 mill

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PROGRAM OUTPUT
NO THERMAL GROWTH

EXAMPLE 1.5

YOUR INPUTS ARE

A= 17.500 B= 24.500 C= 53.000 D= 7.500 E= 30.500
W= .000 X= .000 Y= .000 Z= .000
TARGET DAIL READING = -.006
SIGHT DAIL READING = .012
=======================================================
THE REQUIRED MOVE IS
FOR HORIZONTAL -VE = MOVE TO LEFT FACING THE TARGET
FOR VERTICAL -VE = TAKE OUT EQUIVELANT SHIMS
THE SIGHT INBOARD FEET ADJUSTMENT = .007
THE SIGHT OUTBOARD FEET ADJUSTMENT = .012
----------------------------------------------------------------------------------------------DESIRED READINGS ON DAIL INDICATORS ARE
ON TARGET INDICATOR = .000
ON SIGHT INDICATOR = .000

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THERMAL GROWTH 1.1

For thermal growth we need to know the following:

Off set values of x, w, y & z.

Final desired reading on the dial indicators.

THERMAL GOWTH
+ 10
+ 7.5
OFFSET : (CHANGE +/-)
-

10
W

- 7.5
X

THERMAL GOWTH
3
+

OFFSET : (CHANGE +/-)

Y

5
Z

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THERMAL GROWTH 1.2

A: THERMAL OFFSETS
MEASURED IN FEET
PLANES.
B: FINAL DESIRED
INDICATOR READINGS.
(READ NEXT PAGE)

HAL
A

HAL
A

CAL

CAL

CAL: TARGET COLD

ALIGNMENTLINE.
HAL :TARGET HOT
ALIGNMENT
CAL : SIGHT COLD
ALIGNMENTLINE.
HAL :SIGHT HOT
ALIGNMENT LINE.
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Horizontal scale: 1 Square = 1 inch

Vertical scale: 1 Square = 1 mill

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THERMAL GROWTH 1.3

SAG
+ 16.5

+
5.5
Times 2

+ 11 TIR

Measure the distance

and direction (+) or(-)
FROM the cold
alignment line TO the
sight cold alignment
line.
FINAL DESIRED TOTAL
INDICATOR READINGS
FOR COLD ALIGNMENT

SAG
+ 18

+ 4.5
(CHANGE +/-)

Times 2

TIR
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DRAW THE GRAPH 1.4

THERMALY GROWING MACHINES

A: THERMAL OFFSETS
MEASURED IN FEET
PLANES.
B: FINAL DESIRED
INDICATOR READINGS.
(READ ON THE BACK OF
THIS PAGE)
C: TARGET INDICATOR
MISALIGNMENT
PLOTTED FROM TARGET
CAL.
D: SIGHT INDICATOR
MISALIGNMENT
PLOTTED FROM TARGET
CAL.
E: CORRECTIONS
MESURED IN PLANES OF
FEETS.
CAL: TARGET COLD
ALIGNMENT LINE.
HAL :TARGET HOT
ALIGNMENT LINE.
CAL : SIGHT COLD
ALIGNMENT LINE.
HAL :SIGHT HOT
ALIGNMENT LINE.
MAL :MISALIGNMENT
LINE.

SAG+ 16.5

TIR +
1/2 TIR +

SAG + 18

6
3 C

TIR + 4
1/2 TIR + 4
2
+/-

D
HAL

HAL
A

A
CAL

B
C

A
D E +5

Horizontal scale: 1 Square = 1 inch Vertical scale: 1 Square = 1 mill

CAL
MAL

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A
+8

PROGRAME OUTPUT
THERMAL GROWTH 1.5

YOUR INPUTS ARE

A= 17.500 B= 24.500 C= 53.000 D= 7.500
E= 30.500
W= .010 X= .007 Y= .003 Z= .005
TARGET DAIL READING = .006
SIGHT DAIL READING = .004
================================================
THE REQUIRED MOVE IS
FOR HORIZONTAL -VE = MOVE TO LEFT FACING THE TARGET
FOR VERTICAL -VE = TAKE OUT EQUIVELANT SHIMS
THE SIGHT INBOARD FEET ADJUSTMENT = .005
THE SIGHT OUTBOARD FEET ADJUSTMENT = .008
----------------------------------------------------------------------------------DESIRED READINGS ON DAIL INDICATORS ARE
ON TARGET INDICATOR = .011
ON SIGHT INDICATOR = -.005
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HORIZONTALY
Everything is the same but ignore the bar sag.

0.0

TIR

0.0

TIR
1/2 TIR

1/2 TIR

PLOT

+/-

PLOT

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HORIZONTALY
THERMAL GROWTH

Measure the distance

and direction (+) or(-)
FROM the cold
alignment line TO the
cold alignment line.

+ 3

0.0

+ 2.5

0.0

(CHANGE +/-)
Times 2

Times 2

- 5
+ 6

TIR

FINAL DESIRED TOTAL

INDICATOR READINGS FOR
COLD ALIGNMENT

TIR

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PRACTICE

Graph Paper

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CHAIN ALIGNMENT
+

Sprockets should be true

and vertical.
Both sprockets should
have the same plan. (Cord
should touch all 4 points)
Slack = 1 to 2 % centre to
centre distance.

+
+ +

+
+

EXCESSIVE SLACK
+ WEAR POINT
+
+

+
+

NORMAL SLACK

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ALIGNMENT TIP - V-BELTS

There are four areas of good V-belt maintenance but we will only discuss Alignment in detail:
1. Sheave groove inspection
2. Belt inspection
3. Belt & Sheave alignment
DEFLECTION = 1/64
a) Use dial indicator to verify that Total Indicator Run out (TIR)of
each
shaft
PER
INCH
OF end is no
greater than 2 mils.
CENTER TO
b) Use a dial indicator to eliminate Face Run out of each pulleyCENTER
on its respective
DISTANCE shaft. Adjust
pulley's bushing mounting screw accordingly. Tolerance 1 mil/inch of pulley diameter
c) Use a string, straightedge or better yet a laser line tool to accurately align the pulleys. This
+
+
is achieved by:
- Shimming movable machine vertically to eliminate vertical (top to bottom) angularity (twist
angle) between pulleys.
- Shifting moveable machine horizontally to eliminate horizontal (side to side) angularity
between pulleys
- Shifting moveable machine axially to eliminate axial offset between pulleys.
4. Belt tensioning

BELT ALIGNMENT

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FOR YOUR INFORMATION

A study conducted by one of the worlds largest service companies indicated

that less than 7% of the rotating equipment were aligned to within the
tolerance given by the machine manufactures.

We should try to include EQUATES rotating equipments in this 7%.

EQUATE needs you to refer to all the rotating equipment manuals, specially the
critical equipments before you perform any alignment job on any rotating
equipment.

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CONCLUSION

The cost of an alignment is typically very small when compared to the

cost of the loss of production should a critical piece of equipment fail.
Even with the introduction of portable vibration monitoring equipment
and easy to use laser alignment system, alignment still ranks as one of the
leading contributors to premature rotating machinery failure and lost
production. One of the reasons for this is the neglect (or miscalculation) of
machinery dynamic movements of machinery need to be consider when
aligning.
This problem, of ignoring the dynamic changes in the shaft alignment of
two machines from a Off Line to Running condition, need more attention.
There is mounting evidence that long-standing assumptions are leading to
machine reliability problems. Assumptions such as believing identical
machines have identical dynamic movements, relying solely on the OEM
recommendations, ignoring the possibility of horizontal movement,
assuming growth will be symmetrical and only accounting for the thermal
effect. These assumption need to be changed, and behaviors changed.
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ADDITIONAL INFORMATION

Need more information?

Ask your Colleagues, Team leader, Engineer or MAC.
Read more information books on alignment for more knowledge and
skills.

Thank you!!!

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Flash Cards
1. Shaft alignments means, axis of rotation of one shaft related to the other
shaft to eliminate the effects of mounting errors on the measurement.

TRUE

FALSE

The Answer is True

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Flash Cards
2. Alignment dose not increase the life of the bearings and seal, and not
much money saving is achieved related to maintenance cost.

TRUE

Properly aligned motors and pumps will

last longer, perform better and use less
electricity. Not only will you perform
motor/pump alignment in record time, but
you will also increase the life of your
motor bearings and seals, saving you
thousands of dollars annually in reduced
maintenance costs.

FALSE

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Flash Cards
3. What do you understand by Radial Run Out? ( Click the right answers)

The amount of which a machine shaft can move along its axis .

The amount of face square ness with shaft axis.

The amount of eccentricity in the coupling hub.

Right Answer

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Flash Cards
4. The 3 types of misalignment are:
a) Axial misalignment.
b) Parallel misalignment.
c) Angular misalignment

TRUE

FALSE

The Answer is True

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Flash Cards
5. Soft foot can be ignored while performing an alignment, because soft
foot has no importance while carrying out an alignment.

TRUE

FALSE

Soft foot have to be corrected before

you start any alignment on any
equipment.

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Flash Cards
6. What are the causes of misalignment? ( Click the right answers)

Thermal growth.
Cheap equipment.
Loose tie down bolts.
Pump/Compressor running in opposite direction.
Pipe strain.
Base plate not in level.
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Flash Cards
7. What are the different methods of alignment?
(Click the right answers)

Straight edge and feeler gauge / taper gauge.

Rope and wire.

Rim and Face.
Using outside & inside caliper.
Reverse dial indicator.
Laser.
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Flash Cards
8) Thermal growth is the change in the length of a particular metal as a
result of the change in temperature of that metal. Typically, when a
metal bar is heated, it will get longer.

TRUE

FALSE
The Answer is True

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Flash Cards
9) Bar sag can be underestimated and an approximate reading can be
added to your reading while performing alignment.

TRUE

FALSE

Never under estimate the bar sag.

Always verify by repeating the checks specially when measuring the bar sag.
Never estimate the bar sag. Always do a practical check to find the exact bar
sag reading.
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10) Belt tensioning should be equal too ____ per inch, when measured
from the centre to centre of two pulleys.

1/32

1/64

Right Answer

1/16
1/8

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Flash Cards
11) What is the difference between Soft Foot and Angular Soft Foot?
The first step during an alignment is to check the motor's feet for gaps.
Each foot is checked above and below the shim pack with feeler gages to
determine if the gap between the foot and base is parallel. A parallel gap
indicates regular Soft Foot. A non-parallel, irregular gap means Angular
Soft Foot is present.

TRUE

FALSE
The Answer is True
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