DRAFT ALIGNMENT TUTORIAL Draft of Alignment Tutorial for Presentation at The Texas A&M University 42th Pump Symposium Jack Essinger Acculign, Inc. Willis, Texas 77378 DRAFTDRAFT THIS IS A DRAFT OF MATERIAL PRESENTED TO TEXAS A&M UNIVERSITY FOR A TUTORIAL TO BE PRESENTED AT THE 12TH PUMP ‘SYMPOSIUM IN MARCH, 1995 TUTORIAL ON SHAFT ALIGNMENT Jack Essinger is a consulting engineer with Acculign, Inc. Willis, Texas. Jack holds a Bachelor of Science Degree in Mechanical Engineering from Arizona State University, and, worked as a machinery engineer for Shell Oil Company for 29 years. He founded Acculign, Inc. in 1973, and is a Rogistered Professional Engineer in the State of Texas. He hhas served on a number of API Committees, and is a Member Emeritus of the Advisory Committee of the Texas ‘A&M University Turbomachinery Symposium. ABSTRACT Proper alignment of rotating equipment has long been recognized as a prerequisite to safe, reliable operation. Achieving proper alignment, however, involves much more than merely adjusting the machines #0 that tho shafts are coaxial. It involves the design and implementation of the equipment and of the system into which the equipment is integrated. This Tutorial highlights important issues in design and implementation of the entire system, as well as details, of the final alignment process. INTRODUCTION Virtually every user of rotating equipment recognizes that the safety and reliability of that equipment is greatly influenced by the alignment of the shefts. Improperly aligned equipment, even if well designed, propery installed, and correctly operated, will ail prematurely. With this knowledge, users are generally conscientious in aligning ‘such equipment prior to operation. ‘The emphasis on alignment, however, is often focused solely upon the final adjustments of the equipment after installation and prior to startup. While this final adjustment is a vital part of the overall procedure, itis not the entire Procedure. Forthe alignment to be successful, both the ‘equipment and the overall system must be propery designed, and the installation must be well done. ‘The purpose of this Tutorial is to highlight important items that must be done prior to the final alignment adjustment, as well as to provide some details of the final alignment Procedure. General recommendations for alignment tolerances are also presented. ‘THE OBVECT OF ALIGNMENT The object of equipment alignment is to assure that the ‘coupied shafts are propery aligned under all operating conditions, and that they remain so-aligned throughout the fequired running period of the machines. By proper ‘alignment, itis meant that the shafts are coaxial, within Page 1 tolerance, and that the axial shaft separation Is within tolerance, EQUIPMENT DESIGN To achieve proper alignment, itis essential that th ‘equipment hes been designed and built to facilitate the procedure. In many cases, standard design of the equipment is adequate. In other cases, the required features are ‘mandated by standards such as those of the American Petroleum Institute. There remain many machines, howover, that are not covered by appropriate standards or Specifications, and itis left to the user to see that the designs are appropriate. Mandatory items in this regard include the following: Allowable Forces and Moments: For equipment to which Piping will be attached, its important that the design be ‘capable of absorbing reasonable forces and moments that will be exerted by the piping. Regardless of the adequacy of the piping design and installation, some forces and moments will result and must be handled by the equipment. Adequacy of design involves not only the rotating equipment itself, but the associated baseplates and/or soleplates. They must be of adequate strength, well made, and designed to facilitate grouting * Couplings: Couplings must be of proper design and with ‘adequate spacer length to accommodate normal misalignment, including startup, shutdown, and off-design conditions. Adequate spacer length is one of the most important design features in realizing good alignment. * Lifting Provisions: Provisions must be made for moving the equipment vertically and horizontally during the final alignment procedure. For equipment af small to moderate size, jackscrews may be adequate. Large machines will 'ikely require something more elaborate, such as provisions for hydraulic jacking equipment. * Provisions for Turning the Shafts: It is normally a requirement to turn equipment shafts during the final alignment procedure. For small machines, ths is of ittle concern — they can easily be turned by hand. For larger equipment, however, itis sometimes very difficutt to find a means by which to rotate the shafts. Such provisions, including special tools, if required, should be part of the initial design. ‘* Machined Supports: Machine supports and the mating soleplates or basepiate pads must be machined fiat and coplanar. Additionally, the soleplates or baseplates must be sufficiently rigid to resist warpage during handling and installation, and must be designed to facilitate grouting ‘While these appear to be obvious requirements, they are included here because of the number of industrial machines that are not so manufactured. * Placement of Auxilieries: Placement of instrumentation, Junction boxes, lube and seal oll piping, conduit, tubing, and auxiliaries must be such that they do not interfere with the alignment process. Moreover, they must not restrict liting or lateral movement of the equipment, removal or placement of shims, or installation and rotation of alignment brackets,Achievement of these goals normally requires constant Vigilance on the part of the user during design, manufacture, ‘and installation of the equipment. * Tiking Pad Bearings: For equipment with titing pad bearings, orientation is an important alignment feature. With a joad-on-pad design, Figure 1 (A), the shaft is free to move laterally within bearing clearance, and alignment data is diffcutt to obtain without temporary bearing shime to stabilize the shaft. With a load-between-pad design, Figure (6), the shaft remains stable during the alignment procedure. This arrangement also makes internal clearance ‘checks within the equipment much easier and more reliable, CAD LOAD ON PAD Je oS LOAD BETWEEN PADS Figure 1. Titing pad bearing configurations. While @ load-on-pad design may occasionally be required by rotor dynamics considerations, load-between-pads can usually be supplied without compromise. Ask for it. ‘THE EQUIPMENT SYSTEM ‘As with the equipment itself, the system into which the machines are incorporated hes a pronounced affect upon the ability to achieve and maintain proper alignment. For those involved in the design of systems which include rotating equipment, itis vital that these items be considered from the conceptual stages. For those doing final alignment adjustments after installation, it is important that checks be made to assure that the system is installed as designed, and that design features have not deteriorated. Important items include the following: Page 2 Piping is generally accepted that improperly-designed or oorly-fitted process piping is one of the major causes of shaft misalignment and cther mechanical failures. The insidious nature of the piping problems also make them among the most difficult to find, analyze, and treat. Except in fate cases, itis not possible to determine by visual inspection whether or not 2 problem exists or to evaluate its severity, ‘While piping system design and/or analysis are outside the ‘scope of this Alignment Tutorial, the subject is of such vital importance to proper alignment that some precautionary comments are warranted: ‘* Mechanical Design: Aside from hydraulic considerations, piping design must inciuce a mechanical layout that will permit proper support, guidance, and restraint of tho piping. Additionally, an analysis is requited to assure that the piping is not over-stressed curing installation and operation, and that it does not impose undue forces and moments an the ‘mechanical equipment to which itis attached. istoricelly, the hydraulic and siress calculations were done using very simple calculations and empirical data. The mechanical layout would involve a plan to minimize loading ‘on rotating equipment by using adequate pipe loops to give fiexbilty, and by the judicious placement of supports, guides, and restraints. ‘The advent of computers, however, has had a dramatic affect upon piping design, with much more emphasis on analysis and much less emphasis on basics. ‘The results are mixed. On the one hand, the computer routines offer a means for doing a much more thorough analysis then can possibly be done manualy. In this regard, ‘computer-designed piping can bea blessing. Thereis, on the other hand, a growing tendency to rely solely upon the computer analysis of a piping system without regard to basic ‘900d practice of system layout. In these cases, computer-designed piping can be disastrous. An effective system will included fundamental practices of good layout as Well as a reasonable computer analysis. * An Overall Pian: In designing piping that connects to rotating equipment, itis absolutely essential that the designer have an overal plan for the piping system. Prior to any detailed analysis, the designer must study the application and make some judgments as to what is required. If the piping is to operate at elevated temperatures, for example, the designer must recognize thet pipe loops will ery likely be required to accommodate thermal growth, and such loops must be incorporated in the intial layout. The configuration of the piping loops will ikely change when a detailed piping analysis is done, but at least the piping loops with which to work will be there. ‘Similarly, especially f he plping is large or heavy-walled, it must be recognized that substantial anchors will be required to accommodate piping forces, and the piping must be outed through locations where itis possible to locate such anchors; ie., at grade level. Forces caused by thermalgrowth of large piping can be enormous, and generally cannot be handled adequately in overhead structures, Once an overall pian is established to accommodate hydraulic forces, thermal growéh, and the support of pipe, pipe fittings, and contents, then the computer can be used to ‘efine and optimize the system and the piping will tum out well. To do @ computer analysis on a sysiem that has no overall plan, however, is an invitation to disaster. Such a system simply will not meet expectations. ‘* The Computer Analysis: itis imperative that the computer model adequately depicts the system being studied. In this regard, be aware that all computer models are not the same, nor will all analysts make the same assumptions when using a given computer model. Many times, the analyst may choose to use only a portion of the capabilities of the analytical program, and omission of critical detalis may have a pronounced affect upon the results of the study. Itis common practice, for example, to support piping by welding a steel shoe to the pipe, and having this shoe rest directly upon a steel cross member of a pipe rack. The weight of the pioe end contents is supported by the steal plates, but the pipe is considered to be free to move in lateral directions, Free to move, thats, if enough force is exerted to overcome friction, rust, and paint at the support location. For small piping, it may be appropriate to assume that this arrangement is “frictionless”, and to treat it in that manner in the analytical model. For large piping, howover, the assumption of no friction is grossly inadequate, and a reasonable friction factor must be assigned. Better yet, use pipe hangers instead of shoes when lateral movement is expected; hangers are inherently flexible n the lateral direction. Similarly, itis often assumed that pipe anchors are totally Tigid: Le, that they do not move regardless of the piping force applied. While this may be a reasonable assumption for small piping anchored to a large concrete foundation, it is certainly not true for large piping anchored in a structural steel system well above grade. Some very dire piping problems have risen from this specific erroneous ‘assumptions. In short, there are many assumptions that must be made when using a computer model. Be sure the assumptions are appropriate. Some additional items that should be considered are: + Apply a safety factor to allowable forces and moments on ‘otating equipment. Safety factors are used routinely in ‘mechanical design to account for unknowns and uncertainties. Piping design has plenty of both, and a safety factor of not less than two is recommended, Ifthe calculated forces and moments are no more than one half of the allowable, then the actual forces and moments ultimately may be within limits. Without a safety factor, actual forces ‘end moments are certain to exceed the allowabies. + Make allowances for system deterioration. Differential settlement of foundations Is a fact of life, and should be assessed in the analysis, Itis very common, for example, for a pump and driver to be supported on a monoli Concrete block whereas the piping to the pump is supported Page 3 from an adjacent concrete stab. Differential settlement is a virtual certainty. Similarly, if the main pump and spare bump are on separate foundations, any common manifol Of piping should cor pumps. + Analyze any off-design conditions such as startup, shutdown, or steamout, especially ifthe rotating equipment will be running during these conditions. + Account for thermal movements of the rotating equipment itselt, + For liquic-iled systems, be sure the weight of the liquid is considered. * Additional items: Aside from layout and analysis, a ‘number of additionel items are worthy of mention: + Expansion Joints: in general, the use of expansion joints is to be discouraged, but they sometimes represent the ‘only reasonable solution to certain flexbility problems. Properly-used, expansion joints can be very useful in ‘eccommodating large movements in piping systems. When used improperly, however, they can present some serious problems. «AD | COMPRESSION (BD NHN AAR SHEAR © ffi BENDING Figure 2. Typical methods for using expansion joints. ‘The most common error with expansion joints is in trying to ‘accommadate thermal growth in a piping system by ‘compressing the expansion joint (Figure 2 (A)). in pressurized systems, hydraulic forces within the expansion Joint itself try to push the connecting piping away in bothdirections, These axial forces must be counteracted by tie rods, gimbal joints, or by anchors within the piping system. The magnitude of the axial force Is dependent upon the size of the expansion joint and the pressure within the system, ‘and can be very high even in systems operating at moderate pressures. A 12 inch unrestrained expansion joint operating ‘at 100 psi, for example, will exert ebout 14,000 pounds axial force on the piping system, Similarly, very large axial forces ‘can be generated in vacuum systems using large diameter expansion joints, When they are required, itis generally much preferred to use expansion Joints in shear or bending (Figure 2 (8) and (ey). + Rigid Pipe Supports: Rigid suppor's are generally @ poor choice for supporting piping near rotating equipment. Inherently, a rigid support cannot accommodate even small thermal changes in the piping or the equipment itself without sfecting the forces and moments on the rotating equipment, and these affects can sometimes be very large. This is easy to see, for example, on the inlet piping to a steam turbine. If the support ie adjusted to hancle the weight of the piping in the cold condition, it will be totally ineffective as ‘s00n as the turbine warms up and rises a few thousandth of inch, If't is adjusted to cupport the pipe in the hot n, it will produce a large force on the turbine when the system is cool. Similar analyses apply to virtually all other equipment as well. Spring supports are very much preferred under such conditions since they can ‘accommodate piping and equipment movements with only minor changes in supporting force. Despite the overall advantages of spring supports, it should be noted that they are not without problems of their own. Specifically, spring supports present some unique installationvalignment prablems when they are used to Support large, liquid-filed piping where the weight of the fuid in the piping may be much greater than the weight of the piping tselt ‘As furnished, @ spring support normally has a temporary "stop" that compresses the spring to the calculated service condition; Le,, to the point where the spring is expected to be ‘compressed when supporting the pipe and its contents. The intent is that the stop be left in place unti the piping is. installed and made-up to the rotating equipment, after which the system wil be filled with liquid and the stop removed. Problems arise, however, if the stop is removed prematurely (before the pipe is filled with liquid), or during maintenance When the stop may not be reinstalled before liquid is drained from the system. Care must be exercised to see that the spring support and the stop are properly used. * Make-Up to Rotating Equipment: On initial installation, or if the piping or equipment has been removed for maintenance, itis important to assure that the final make-up of flanges to rotating equipment is properly done, Most users have a spectfication covering the maximum allowable equipment movement resulting trom piping make-up, and It {a generally a requirement that a mechanical inspector or craftsman witness the piping installation Poge4 Typically, dial indicators are used to monitor vertical and horizontal shaft movement as the piping is being installed. ‘These dial indicators are sometimes mounted on the brackets that wil ultimately be used for alignment of the equipment, or they may be mounted from the baseplate. Allowable tolerances vary among users, but normally run in the range of 0,002 in to 0.003 in total indicator reading a8 the maximum allowed. If the equipment moves more than the allowable tolerance during piping make-up, corrective action must be taken. ‘= Piping System Inspection: Aside from the actual fi-up of piping to the rotating equipment, itis important to see that ‘the entire piping system is complete and functional before the actual alignment procedure is started. This check should include the following: += Is all piping properly made up with gaskets and all flange bolts tightened? + Are hydrotests done and slip binds removed? + Are all pipe gi in good condition? 3, Supports, and restraints in place and « Is the piping system liquid-flled (very important for large piping)? + Are spring supports adjusted and within the proper operating range? Are stops removed? (See discussion, under Rigid Pipe Supports, above). + Is all auxiliary piping made up (even small piping can, affect alignment)? + Is piping insulation completed? ‘Supporting Structure Prior to the actual alignment procedure, itis essential that the supporting structure of the equipment be inspected to assure that itis in good working order. While a semblance of alignment may be achieved with a flawed supporting structure, the long term results will cortainly be less than expected. Proper alignment cannot be achieved unless the equipment is properly supported. ‘While details of this inspection may vary greatly depending Upon the design of the actual equipment, the following items should be observed: * Concrete Foundations: Concrete foundations should be checked for general deterioration including cracks, sloughing, exposed reinforcing steel, oil-soaking, or evidence of foundation settlement. If such problems appear, they should be evaluated and corrected as necessary, Be especially mindful of installations where the two pieces of equipmenttto be aligned rest upon separate foundations, or ‘where major auxiliary equipment such as the condenser for ¢ steam turbine is on a foundation not integral with that of the turbine, With such arrangements, differential settlement of foundations may cause very serious alignment problems‘even though the individual foundations may be in excellent condition. * Structural Stee! Supports: For equipment mounted on structural steel, the supporting structure should be inspected {or deterioration such as rust, welding cracks, damaged structural members, and mi field modifications that may have altered the characteristics of the original installation. Significant field welding and/or flame cutting can cause serious distortions not only to the supporting structure, but to the rotating equipment mounted upon it. Be aware of the routing of hot piping in and around the structure. Uninsulated or poorly-insulated steam lines, for example, can cause significant structural distortion wnich may affect equipment alignment. Se aware, also, that lubricating oil and seal oil tanks built into the steel structure may be sources of alignment problems, especially for equipment mounted on or directly above the cil reservoir. White itis not always feasible to eliminate these potential sources of distortion, except in the initial equipment design, the knowledge that they.exist should alert the user to monitor the equipment closely. Grouting ‘Once placed, itis often difficult to judge the quality of grouting. A visual inspection should be done, however, to ‘assure that the grout is complete and in apparently-good condition. items of concer include cracking, crumbling, Voids, apparentooseness, and oil-soaking. if any of these probiems exist, corrective action should be taken, Foundation Botts Foundation bolts must be tight. Once installed and properly tightened, foundation totts should never become loose under normal operating conditions. if loose foundation bolts are found, investigate and correct the cause. Such looseness may be caused by grout deterioration, rusting, foundation bolt yielding, or other causes. Whatever the cause, itis not advisable merely to re-tighten the bolts ‘without further investigation. ‘Shims and Hold-Down Bolts ‘Shims and hold-dewn bolts are vital inks between the ‘machine and the foundation. itis important that every shimpack and hold-down bolt in the equipment train be checked, not just the ones on machines thet are to be moved to achieve alignment. Typically, this inspection is done one shim location at a time, Remove the hold-down bolt and raise the equipment sufficiently to remove and inspect all shims at that location. The following recommendations are offered: * Hold-Down Bolts: Clean, inspect, and lubricate the hhold-down bott. Assure that the bolts are of the proper length; Le,, long enough to assure a minimum thread engagement approximately equal to the bolt diameter, but short enough so as not to "bottom-out" when tightened. At the same time, assure that the equipment is not that there is sufficient room for lateral ‘Movement of the equipment to achieve alignment. To ‘assure room for lateral movement, some users require that a spacer be installed around the hold-down bolts during initial installation and initial alignment. The spacer is removed prior to final alignment, thereby assuring that the hold-down bolt is reasonably centered in the bolt hole. While most specifications prehibit undercutting of bolts to achieve lateral movements, it is sometimes the only practical solution once the equipment is installed. If undercutting, must be done, bolt diameter should never be reduced to less than the diemeter at the thread roct. Care must be exercised ‘o assure that undue stress risers are not introduced during undercutting. Adequate mechanical inspection during Initial equipment installation will eliminate the problem altogether ‘* Washers: Assure that washers on the hold-down bolts are in good condition and that they are heavy enough so as not to distort when the bolts are tightened. In many cases, standard flat washers are inadequate for this service, and special heavy-duty washers may be required. Two-pioco spherical washer sets (equalizing washers) are sometimes Yery useful. These commercially-available washers are ‘much more resistant to distortion than are standard washers. + Shimpacks: Shims must be of materials that do not. corrode or rust in a normal plant environment. Brass shimstock has been conventional for many years, but stainless steel shimstock is currently preferred by most Users, and is a requirement of some specifications, including those of the American Petroleum Institute (API). Moreover, pre-cut shims are now widely used on small to moderate-sized equipment and are generally recommended because of their uniformity and ease of use. Most users also feel that they are cost effective. + Use as few shims as possible. itis much better to use a ‘few shims of greater thickness than to use many thin shims. Even with uniform shims of high quality, the more shims that are used, the harder it is to get full compression. Many company specifications limit the number of shims that can be used. A maximum of five or six shims is typical. Some ‘companies also require one relatively thick (1/8 in) chim at ‘each location to assure that it is possible to make a relatively large vertical movement of either machine should that become necessary. Many times, this thick shim has proved to be very valuable when an "identical" spare or replacement ‘machine is installed and Is found to have a shaft centerline elevation different from the original Conversely, many users prohibit the use of extremely thin shims because they are difficult to handle, and can easily become folded or wrinkled at installation. Typically, there is no need to use shims thinner than 0,002 in. Inthe final shim sandwich", place thicker shims top and bottom, with thinner shims in the middle. « Assure thet the shims are clean, of uniform size, and free of hammer marks, wrinkles, and burrs. Equally important, ‘see that the mounting surfaces of the equipment and the basepiate/soleplate are ciean, tree of rust, and in generally ‘good condition.+ Use shims of an appropriate size, Shims that are too ‘small will not adequately support the equipment. Shims that aie too large cannot be properly compacted by the hold-down bolts. For most equipment, the ize of the shims will approximate the size of the machine support. Notable ‘exceptions are some electric motors that have a continuous ‘supports for the full length of the motor. The manufacturer of such equipment should be consulted for specific. recommendations. Generally, however, shim such ‘equipment only at hold-down boit lecations. + Its typical of the design of some large machines that. ‘one or more of the supports remain free to move laterally ‘and/or axially during operation to compensate for thermal movernents of the equipment. For such machines, inclusion of a shim of glass-reinforced Teflon® has proved useful in assuring low-fricion movement. * Parallelism of Supports: Check for parallelism of the machine supports and the corresponding surfaces on the baseplate/scleplate. A visual inspection wil reveal gross problems. 4 feeler gauge inspection is more precise. With the machine resting upon the shims, but not tightened down, assure that a feeler gauge of approximately 0.002 in cannot be inserted between the machine support and the shims. If the feeler gauge can be inserted as come locations ona ‘support but net at others, itis an indication of ‘non-parallelism of support surfaces, Ifthe non-parallelism of supports is excessive, it may present a problem that is not easily solved, especially when Telatively large equipment is concemed. It is one of the problems that should have been detected and corrected at Initial installation, but such is not always the case. The solution may require remachining of the equipment supports or baseplate/soleplate, regrouting, or both. Tapered shimpacks are sometimes used as an expedient, but are seldom @ satisfactory long-term solution, Once again, the presence of a good mechanical inspector during installation would have eliminated the problem. * Bolt Tightening: Tighten all hold down bolts to the prescribed torque value. Use good practice in tightening the bolts; ie, tighten botts sequentially to about 60 percent of the final torque value, then £0 percent, then 100 percent. ‘Casing Distortion (Soft Foot) Aside from parallelism of the support surfaces, itis also vital that the correct thickness of shimpack be used at each location to assure that the equipment is not distorted when the hold-down bolts are tightened. This check for distortion is normally referred to as @ Soft Foot Check. Details depend upon the size and type of equipment to be checked as noted below: ‘* Small Equipment For equipment with torsionally-rigid casings (stich as most API and ANSI process pumps and their drivers), itis customary to conduct the soft foot check at each machine support. This check is usually done immediately following the installation of shimpacks and the tightening of hold-down bolts. To do this check, mount a dial indicator on the baseplate with the indicator stem resting atop the equipment support (See Figure 3). A magnetic Page 6 base is very handy for this check, but it must be substantia! ‘and must be rock-solid to assure good readings. Loosen the hhold-down bott at that location, and note the amount of rise fof the support. Ifthe support moves more than about 0.002", itis an indication that the casing is being distorted, and that additional shims are required at that location Conversely, if there is no movement at all when the bot is Icosened, it may be an indication that there are too many shims at that location. Add or remove shims as required, and repeat the procedure at each machine support unti the desired results are obtained. When properly shimmed, the support movement at each location should be approximately equa. Figure 3. Dial indicator arrangement for distortion (soft foct) check. Remember, this is @ check for casing distortion. {tis vital to the good mechanical health of the equipment, and it must be ‘conducted on each piece of rotating equipment in the train (58 precautions for gears, below). * Moderate-Sized Equipment: For larger pieces of equipment where the casings are not as torsionally-rigd (moderate-sized centrifugal compressors and condensing steam turbines, for example), provisions for field-verification Cf casing distortion should be included in the design. Many ‘options are available. Optical targets can be provided that, ‘can be checked during factory assembly and re-checked in the field. Alternatively, specially-machined flats for precision levels can be supplied at several locations on the equipment. For horizontally-split machines, these flats can be provided merely by extending the lower flange out about two inches further than the upper flange. These flats have proved to be Very useful in detecting twisted casings during installation. For machines having four support locations, end for which no checking provisions have been made during manufacture, a relatively simple test for gross distortion can be done as follows: With three supports tightened down, remove the shimpack from the fourth support. Measure and record the thickness of the shimpack. Remove the temporary support at this location. Using feeler gauges, measure and record the ‘gap between the machine support and baseplate/soleplate. Subtract the feeler gauge dimension from the shimpack thickness, This is the total deflection of the machine casing at that location with no support. Reinstall the shims, then repeat the procedure at each of the other three support locations. Compare results. Differences larger than about ten percent at any of the four supports may be an indication that the casing is distorted as-shimmed.* Large Equipment: For very large equipment (large centrifugal compressors, for example), yet other techniques must be employed. If specific provisions have not been included in the design, it may be necessary to partially dismantle the equipment to check for distortion. Discuss the ssue with the technical representative of the equipment manufacturer. * Equipment with Gearing: For equipment trains employing gearing, extraordinary precautions are required with regard to setting the gear case and aligning the gearing. Only with very small, low-speed gearing Is the normal soft foot check applicable. For virlually all other gearing, ‘acceptance criteria must be based upon gear tooth contact, and not upon casing distortion. In some instances, it may actually be necessary to introduce slight casing distortion in order to get proper tooth contact. In virtually all cases, the recommended procedure is to install the gearcase, assuring that proper gear contact hes been achieved, and then align other equipment to the gear. Do not move the gearcase once ithas been installed and Proper tooth contact verified. EQUIPMENT SURVEY In addition to assuring that the system is complete and ready for the alignment process, itis equelly important to determine that the rotating equipment itself is ready. While this admonition may seem trite and unwarranted, it is made ‘on the basis of experience to the contrary. It is not uncommon for alignment attempts to be made on equipment thatis simply not ready to be aligned. It should be noted that the alignment procedure is likely to be slightly different for equipment which is being installed for the first time, and equipment which is being aligned during ‘normal maintenance. For new equipment, alignment is neatly always dane before any significant piping is bolted-up to the equipment, and the alignment is then monitored as the piping is fitted. This is an important step in assuring that the biping does not impose undue stresses upon the rotating equipment in the cold condition. For equipment that has been in service, however, alignment checks are often done with the piping connected. While some would argue that the piping should be unbolted for, 3nment re-checks, that may be neither practical or desirable. Ifthe machine has no history of alignment Problems, and i the re-check reveals that the alignment is Satisfactory or that only small correction there is really little reason to remove the piping. If, on the ‘other hand, the machine has a history of abnormal maintenance and reliability problems, and/or if pipe strain is ‘Suspected, then it is probably worth the effort to remove Piping prior to the alignment re-check. The user must make the decision on a case by case basis, Among the items that should always be verified before final ‘alignment are the folowing: * See that the machines to be aligned are totally ‘assembled including seals, bearings, and small auxiliary piping. Disengage seal locks, if used Page 7 * Assure that the shafts of bath machines rotate freely. With pressure-lubricated systems, it is good practice to circulate lubricating oil during the alignment process. * Inspect the coupling to assure that it is complete, clean, and in overall good condition. Pay particular attention to the flexible elements of the coupling to assure that they are not damaged. Also inspect coupling bolts and nuts to assure that they are the right sizo and that they are clean and well lubricated. For high speed couplings, assure that the bolts and nuts are from weight-matched sets. If the coupling hubs have not been installed, see thet shaft extensions are clean, free of rust and burrs, and that the diameters are within tolerance. Check shafts for runout. Typically, shaft runout should be well under 0,0008 in Similarly, check coupling bore dimensions. Assure that all items are clean and free of burrs, See that keys (if used) are of proper size and length, and that they mitthe keyways properiy. After installation of the ‘coupling hubs and keys, check the runout of the outside diameter of the hubs as well as the face. For fully-machined couplings, these runouts are typically on the order of 0.001 in, although some users specifications may allow as much as 0.002 in on low speed applications. For general-purpose couplings that are not fully machined, runouts may be considerably higher. ‘SELECTING AN ALIGNMENT SEQUENCE During the early stages of the alignment procedure, itis necessary to determine which machine is to be moved to improve alignment. If only two machines are invalved, the decision is usually fairly easy. With motor-driven pumps, for ‘example, itis virtually universal that the motor would be moved. First and foremost, the motor does not have process piping to worry about. Secondly, it is just plain ier to move a motor than to move most pumps. As the equipment becomes more complex, however, 50 does the selection process. if the process pump is driven by a steam turbine rather than an electric motor, then the decision may net be so clear. In this case, both machines have piping with which to contend, and the decision must be made on other factors, If the pump is simple and operates at ambient temperature, it would probebly be logical to move the pump. If itis a multi-stage pump handling a hot product, then it may be easier to move the turbine. If you can't decide, it probably makes no difference. While all rules in this regard are flexible, the following are generally followed: * Move motors instead of other equipment. ‘* Move driven equipment instead of steam turbines. * Move equipment with no process piping if possible * Move equipment that operates at ambient temperature rather than equipment that operates at elevated or reduced temperatures,* Use special care if @ gearis involved. Geers require special care to assure that alignment of the gear mesh is Proper. Once the gearis properly installed, do not move it. In virtuelly every case, the gear should be installed and other equipment should be aligned to the gear. * For long equipment trains, i is sometimes useful to start near the middle and align both ways. In aff cases, itis essential to do a preliminary (rough) alignment on the entire train before doing the final alignment at any coupling. The consequences of omitting the rough alignment step is obvious; if there is no room to move the last machine in the train, you start over. SELECTING AN ALIGNMENT METHOD. The term “alignment method" refers to the method used to determine the relative position of the machines to be aligned, Most commonly-used conventional methods use mechanical dial indicators @s the primary measuring tool, although, micrometer methods are useful for some types of couplings. Additionally, specialized laser alignment systems are avallable and are fairly widely used, The specific method to be used in any alignment situation 's dictated by a number of factors such as the type and size of the machines being aligned, the type of coupling, the avaliabity of alignment tools, the training and experience of the craftsmen, and the specifications of the user. For this tutorial, however, only conventional alignment methods will be discussed, and only the two most common methods will be treated in deta i.e, the Face & Rim Method and the Reverse Incicator Method. The Face & Rim Method For this well-known and widely-used method (Figure. alignment bracket is attached to one of the machine shafts, (0F coupling hub) and extends to the proximity of the ‘coupling hub on the other machine. Dial indicators aro affixed to the bracket, as shown, with the stem of one Indicator resting upon the face of the hub, and the stem of the other indicator resting upon the outer diameter (the rim) of the same coupling hub. = Figure 4. Face & Rim Method. Typical bracket and alal indicator arrangement. Page 8 To determine the relative shaft alignment of the two machines, itis customary to null (zero) the dial indicators at ‘the uppermost (top) position, and then to rotate both shafts in 80 degree increments so as to get a complete “set” of dial indicator readings et the top, both sides, and the bottom tons, Data from the dial indicator reading on the rim are used to determine the relative radial pesition of the shaft ‘centerlines in the plane of this dial indicator. Dial indicator readings on the face of the coupling hub reveal the angularity of the two shafts. Using these data and the machine ‘dimensions, the user can determine the shim changes and horizontal movements required to achieve proper alignment. Details are included in following sections. Advantages of this method include: + The method is intuitive, simple, well known, and easily understood, + It normally works well when coupling spacers are short =, and hub diameters are large. Disadvantages of this method include: + Accuracy is lost if hub diameters are small + Face readings are affected by axial movement flost) in either or both shart. + Typically, the coupling spacer must be removed. + Data may be affected by inaccurate coupling geometry. Use of this method is generally discouraged for high-speed, high-horsepower equipment, for couplings having long spacers, for couplings having small diameter hubs, or for equipment where shafts may have axial movement. It should be noted that equipment using antisriction bearings may stil have some axial float, although itis generally not sufficient to cause a problem Reverse Indicator Method ‘The Reverse Indicator Method is shown in Figure 5. The crigin of this method is obscure, but itis known to have been Used to a limited degree for many years. Over the past two decades, however, the method has become very popular and is considered by many users to be inherently more accurate ‘and reliable than the Face & Rim Method. With this method, alignment brackets are secured to the ‘shaft or to the rigid coupling hub of one machine, and extend over the coupling spacer to the rigié hub (Figure 5(A)), or to the alignment bracket (Figure 5(B)) of the other machine. Dial indicator readings are taken in the radial direction only — no face readings. As with other methods, itis customary to "zero" the dial indicators at the uppermost (top) position, and then rotate both shafts in 90 degree increments so as to get a complete "set’ of readings at the top, both sides, and at the bottom. Data from thesa dial readings yield information regarding the relative offset of the shaft certerfines in the planes of the two dial indicators. Using these data and machine dimensions, the user can determine the shim changes and horizontal movements required to achieveProper alignment. Again, details sections, CAD .¢ given in following Figure 5. Reverse Indicator Method. Typical bracket and dial indicator arrangement. Advantages of this methed include: + The coupling spacer need not be removed. + Data is more accurate if coupling spacers are long. + Data is more accurate if coupling hubs diameters are small + Readings movements. e essentially unaffected by axial shaft Disadvantages of this method include: + Limited access to shafts may make brackets difficult to fit + The method is generally not suitable for couplings with very short spacers. + For most people, interpretation of the data is not intuitive, This method is normally recommended for high-speed, high-horsepower equipment, and is especially applicable ta couplings with long spacers and small diameter hubs. The method should not be used, however, unless there is @ feasonable distance between the planes of the two dial indicators. If this distances too short, the ability to determine angular misalignment will be diminished; it is the Page 9 corollary to the problems associated with a small diameter hub when using the face and rim method. As a general rule, this method should net be used if the distance between dial indicators is less than the diameter of the hub upon which face readings would be taken. ALIGNMENT TOLERANCES Sources for Tolerance Recommendations Unfortunately, there are no universal standards for alignment tolerances. While recommendations exist from @ number of sources, there is little general agreement on what ‘such tolerances should be, or how they should be measured. ‘Some sources of such information are: * Coupling Manufacturer's Data: Virtuelly all coupling ‘manufacturers publish recommendations conceming the maximum misalignment to which their couplings should be subjected. For standerd production couplings, these ratings are normaly listed in the manufacturer's catalog or in published technical bulletins. For special, high-performance couplings, the maximum allowable misalignment is normally ‘shown on the coupling drawing The misalignment ratings vary greatly depending upon the type and size of coupling, and upon the specific manufacturer. Generally speaking, however, the ‘manufacturers allowable misalignment has to do with the capabilities of the coupling itself as opposed to considerations of the coupled equipment. In most cases, the misalignment allowed by the manufacturer fer exceeds the misalignment that would be allowed by the user. * Textbooks, Reference Books, and Technical Papers: Specific recommendations are given in a number of excellent technical publications on coupling alignment, such as Total Alignment by V. R. Dodd, and The Shaft Alignment Handbook by John Pictrowskl (See the bibliography). Typically. these recommendations are based upon user Consensus as modified by the individual experiences of the authors. While the recommendations vary in detail, they generally reflect allowable tolerances that will assure trouble-free operation of a wide variety of rotating equipment. Readers are urged to review the referenced publications. * User Speciications: Many user companies have developed alignment specifications that reflect allowable tolerances. These specifications are usually drawn from experiences within the company, and normally reflect the Consensus of technical personnel within the organization. Reeders may wish to evail themselves of such in-house specifications, * PIPIAP|RP686. This Recommended Practice for Machinery Installation remains unpublished at the time of this writing, butis certain to contain recommended alignment tolerances. Precautions in Applying Specifications Important factors that should be considered when applying alignment tolerances include criticality of equipment, rpm, horsepower, coupling type, and coupling spacer length. Vitalequipment, high rpm, and high horsepower usually demand closer alignment tclerances than do routine, low-rpm, lovehorsepower machines. Coupling type and spacer length also play Important roles. Other things being equal, machines with longer coupling spacers are more tolerant of ‘misalignment than are those equipped with short spacers. The specific type of coupling also plays a role, but is generally of less importance than is spacer length. Specifications for alignment tolerances should recognize and incorporate these factors, and should be establisned so as to assure adequate and consistent alignment for the application without being over-restrictive. Moreover, the specification should be simple, easily-measured, and easily-monitored. Unfortunately, it is seldom aasy to meet all these criteria, and many of the commonly-used ‘specifications lean toward the side of simplicity. Some examples are as follows: + Dial Indicator Readings: An often-used acceptance criterion for misalignment is merely a maximum allowable dial indicator reading. A typical specification may reed “Maximum allowable dial indicator readings shall not exceed 0.004 in TIR (Total indicator Reading) for equipment 0 0 RIGHT ¢ 2 Oe 2)0 "She 4 0 0,938° a g Hi 0 RIGHT Se . 4 SIDE 8 0.938° = Figure 6. Face & Rim Method. Inconsistencies when applying simplified acceptance criteria, Page 10 ‘operating 1,800 rpm or less, and 0.002 in TIR for equipment ‘operating in excess of 1,800 rpm". While the specification addresses equipment rpm ae an important eriterion, i does not address the method by which data is ta be taken, nor ‘does it consider coupling geometry, both of which are vital, Figure 7. Reverse Indicator Method, Inconsistencies when epplying simpitied acceptance criteria. The appeal of such a specification is its simplicity. itis easy to understand and to monitor. Beyond the simplicity, however, such a specification is of little value. It assures neither proper alignment nor uniformity. Such specifications should be discouraged. Please refer to Figure 6 which depicts machines being aligned by the Face & Rim Method. As is typical with alignment measurements, dial indicator readings are shown in mils (1 mil = 0.001 in). Indicator readings on the rim of the coupling are shown on the outside of the circle; face readings are shown on the inside of the circle, The right-hand side of the equipment train is identified. ‘Assuming that the elignment criterion is a maximum indicator reading of 0.004 in, the alignment of the machines in Figure 6(A) would be satisfactory, Now refer to Figure 6(6) where the dial indicator bracket has been reversed to read on the opposite machine, While the relative position of the two machines remains‘unchanged, the readings now show the alignment to be unsatisfectory. The inconsistency is readily apparent, as is the unsuitability of the simple acceptance criterion, Next, please refer to Figure 7 for machines being aligned by the Reverse Indicator Method. When using this method, itis ‘customary to present the dial indicator readings on the outside of two separate circles as shown. The right-hand side of the equipment train is designed by the "R” in the ircle. Again, the readings are in mils. Using the same acceptance criterion of 0,004 in maximum indicator reading, the alignment of the equipment in both ‘cases is satisfactory. The dial indicator readings are, in fact, identical. Note, however, that the angular misalignment of the coupling in Figure 7(B) is twice as great as in TIA) because the length of the coupling spacer differs. Again, the inconsistencies are evident. Consistent acceptance criteria, ‘simply cannot be based solely upon dial indicator readings. © Offest and Anguiarty: Another relatively common specification places limits upon what is called parallel offset ‘and angulanty. Such a specification may read, for example, *Maximum allowable misalignment shall nat exceed 0.004 in total indicator reading, plus 0.002 in per foot engularity”. 0 RIGHT c 2 ‘SIDE q PARALLEL pre ces, ANGULARITY Lf PARALLEL OFFSET = 2 MILS ANGULARITY = 12 MILS PER FOOT Figure 8, Face & Rim Method. Defintion of paralel offeet ‘and angularity. ‘This specification is relatively easy to understand and implement when using the Face & Rim Alignment Method as ‘shown in Figure 8. The parallel offset is determined from the rim reading (actual offset is one half ofthe dial indicator difference). Angularity is determined from the face readings. ‘While the specification is probably very poor, itis understandable. When other alignment methods are used, however, such as the Reverse Indicator Method, it is much more difficult to understand and to implement. Specifically, the so-called paralel offset is vague, at best, and becomes meaningful only If further defined in some manner. Except when used Page 11 with the Face & Rim Method, this type of specification is not ‘only poor, but is also vague. Recommendations First, itis the recommendation of the author that industry re-think the continued use of the term paralel offset when ‘establishing alignment criteria. While the term has som. ‘meaning when dealing with the Face & Rim Method, itis largely meaningless and very confusing when dealing with ‘other methods. The sooner we rid ourselves of theterm, the ‘quicker we vill be able to write really meaningful alignment specications. Much more meaningful criteria can be established by considering the angularity of the coupling spacer with respect to each of the coupled shafts, and by tempering the acceptable angularity with items such as coupling type, rpm, horsepower, and crticality of application, A spacer coupling accommodates shaft misalignment by angular deflection of the flexible elements (geers, discs, diaphragms, etc.). The amount of deflection is dependent upon the specific misalignment of the equipment, and the length of the coupling spacer. Please refer to Figure 9 which depicts misalignment of coupled machines in the vertical and horizontal pian MACHINE A MACHINE B VERTICAL 0.006" 0.01 1 = | HORIZONTAL ricHTf 0.002" Figure 9. Misalignment of coupling spacer with respect to coupling shafts. Inthis exemple, the coupling spacer length (the distance between flexible elements) is 12 in, Misalignment ofthe coupling spacer with respect machine A resutts from the vertical and horizontal offsets of the spacer at the plane of the flexible element at machine B. Misalignment of the ‘coupling spacer with respect to machine B results from the Vertical and horizontal offsets of the spacer at the plane of the flexible element at machine AConsidering the misalignment of the coupling spacer with, respect to machine A, it can be seen that the vertical component of misalignment is 0.006 in, and the horizontal component is 0.002 in. The total misalignment of the coupling spacer with respect to Machine A is: {0.006in? +0.002in? =0.0063in ‘The total misalignment of the coupling spacer with respect to machine B is: {00127 +0,008i? =0.0144in. It is most convenient to express spacer-to-shaft misalignment as a ratio of offset to spacer length. In this case, the controlling (largest) misalignment would be 0.0144 inches for a 12 inch spacer, or 0.0012 inches per inch of spacer length. If degrees of angularity are preferred, 0.0012 Inches per inch of spacer length is 0.008 degrees, Having determined the unit misalignment, the data can be compared to established acceptance criteria. As noted earlier, there are no universally-recognized standards with which to compare data, but a review of data from various sources would suggest tolerances approximating those shown in Table 1. Please note that these recommendations are for the maximum misalignment of the coupling spacer with respect to either of the coupled shafts, and that they represent the resolved angularity: i., vertical plus horizontal. Maximum | Maximum | Maximum Unit RPM | Angularity, | Offset of Spacer Degrees_| Inches per Inch 1,800 | 0.086 0.0015 3,600 | 0.057 0.0010 10,000 | 0.043 0.00075 Table 1. Recommended alignment tolerances. Alignment values reflect maximum resolved angularty of vertical plus horizontal offsets. ‘The user will probably wish to temper these date basis criticality of equipment, type of coupling, personal experience, ete. Itis the experience of the author, these tolerances are readily-achievable, and generally quite conservative. It is highly unlikely that normal industrial equipment aligned to these tolerances will ever suffer misalignment problems, with the following possible exceptions: + Equipment employing solid couplings may require closer tolerances. + Equipment suffering from unusuelly-senstive rotor dynamics. While the recommended shaft-to-spacer criteria will yield better and more consistent results than will simpler criteria ‘such es dial indicator readings, interpretation is slightly more difficut and involves some minimal calculations. As an aid in this regard, Appendix A is a Basic Language program listing Page 12 that wil do the calculations for both Face & Rim and Reverse Indicator Methods. Appendix B is a sample printout from this Basic Language program. ALIGNMENT BRACKET REQUIREMENTS General Requirements Virtually all alignment methods using dial indicators require some type of bracket or brackets to affix the indicators to the equipment being aligned. Such brackets may be of a Universal-type available from a number of manufacturers, or they may be fabricated specifically for one application. It is common to use commercially-available brackets for equipment of small to moderate size, and to use sspecially-designed brackets for large equipment. Regardless of bracket details, they must be rigid, fit the equipment property, be easy to use, and be in good mechanical condition. They must not damage shafts or couplings. Makeshift tools, brackets with excessive sag (see discussion below), magnetic bases, and non-repeatabie tools should never be used. Avery simple test can tell a lot about the sultabilty of brackets. Afterthe bracket is installed and the dial indicator zeroed, shake the essembly a few times — not enough to bend anything, but just enough to assure yourself that the ‘everything Is tight and that the dial indicator reading will retum to zero. If the bracket fails this simple test, don't use it, Bracket Sag ‘The defiection of a bracket due to its own weight and the weight of the dial indicators is referred to as bracket sag. With reasonable brackets, this deflection is too small to be readily visible, but is usually sufficent to cause significant errors in the dial indicator readings. To compensate for these inherent orrors, bracket sag must be measured and accounted for in the alignment procedure. It Is typical to ‘measure sag in various brackets es follows: * Universal brackets: A typical arrangement for measuring ‘sag in universal brackets is shown in Figure 10. The bracket is clamped to @ rigid piece of pipe or barstock that is approximately the same diameter as the shaft or coupling upon which the bracket will be clamped in service. The cial indicator to be used in the alignment procedure is fastened to the bracket with the indicator stem resting upon the top of the pipe or barstock, and set to zero (Figure 10(A)). The entire assembly is then rotated 180 degrees so that the indicator stem now reaches up to touch the pipe or bar (Figure 10(8). The dial indicator will now show a negative reading. The absolute value of this reading is known as the bracket sag. If, for example, the indicator is zeroed at the top and reads -0.004 in when the assembly is inverted, the bracket sag is said to be 0.004 in. Since the deflection of the bracket is affected to som degree by the clamping arrangement, it is important the pipe ‘or Darstock being used Is approximately the same diameter s the shaft or coupling to which it will be clamped in service. Severe deviations will likely affect the resultsINDICATOR READING ZERO CAD og Fi PIPE OR aa BARSTOCK. & «BD INDICATOR READING -4 MILS_] Figure 10. Sag check for universal alignment bracket. * Special Brackets: The clamp of special brackets is normally bored to a specific diameter to fit the machine shaft or coupling hub, Please refer to Figure 11. The method for determining sag in special brackets is identical to universal brackets except for @ requirement that a be turned specifically to fit the bracket. Since this is a bracket made for a specific application, the amount of sag, once determined, should be permanently marked upon tha bracket. a & TUBING GR BARSTOCK TURNED TO FIT THE BORE OF THE SPECIAL BRACKET Figure 11. Sag check for special-purpose alignment bracket. ‘* Face-Mounted Brackets: Although reverse indicator brackets have become very popular in recent years, there are stil applications that require face-mounted brackets, and there are stil some who profer this method, even on very large equipment. While the sag of wel-made brackets of this type can be quite smal, it stil essential that it be checked. Fl errs Figure 12. Sag check for face-mounted alignment bracket. Page 13 The normal method for checking such brackets is shown in Figure 12. After checking to see that the tallsiock spindle is ned with the headstock, the bracket is mounted in a lathe ‘as shown, and turned about the tailstock spindle to check ‘sag. The amount of sag should be permanently marked on the bracket for future reference. * Quill Shafts: There are a number of industrial machines such as centrifugal compressors for refrigeration services and small screw compressors that are driven through quill To achieve tend to be long and of quite small diameter. Typically, they are flanged at one end and splined at the other. In aligning such equipment itis customary to have the flanged end bolted-up to the equipment, and to fasten a dial indicatorto the splined end to measure alignmentto the adjacent machine. QUILL SHAFT: PLATE WELDED TO PIPE OR BARSTOCK Figure 13. Sag check for quil shatts. By design, such shafts are very, very fiexible. Most often, sagis significant and must be measured and accounted for. Please refer to Figure 13 for a typical arrangement for checking sag with this type of coupling. * Precaution: it was stated earlier that brackets with ‘excessive 8ag should not be used. Since sag must be ‘measured and corrected in any event, the requirement for minimum sag is sometimes questioned, ‘The reason for the requirement of minimal sag is one of repeatability of measurements. If the bracket is rigid (lit affects of friction and spring constant in the dial indicator are ‘of very litle concem. Ifthe brackets are flexible, however, readings may be affected greatly by the characteristics of the lal indicator itself. Typically, good brackets will sag no ‘more than 0.008 in to 0.010 in, although brackets for very long spans may exceed these figures. Brackets showing sag ‘greatly exceeding these figures should be checked for Tepeatabilty of data, ‘TAKING AND RECORDING READINGS Having completed the preiminary checks on the systom and the equipment, it is time to take readings to determine the relate positions of tne machines to be aligned. ‘The general procedure is as follows: * Secure or prepare the documents upon which alignment readings will be recorded as they are taken, The importance of this often-ignored step cannot be overstated, A well designed, logical, and complete form is an invitation to take{good alignment data. An il-prepared form, or no form at all, |e an invitation to errors, wasted time, and poor alignment. Figures 14 and 15 are examples of a typical forms that ‘may be used for routine equipment where thermal growth is ‘expected in the vertical direction only, and where such growth is expected to be uniform; i same vertical growth at each end of the machine. ‘The form must include ‘Spaces in which to record equipment identification, machine dimensions, expected thermal growth of each machine, bracket sag, coupling spacer length, date, a comment Section, and a place for the signature of the craftsman taking the data. To avoid confusion, a different and specific form should be available for each type of alignment methed that may be used. For vital equipment such as large turbocompressor trains, thermal movement may be expected in beth vertical and horizontal directions. Moreover, itis common that the thermal growth is non-uniform: Le, dtferent at each end of the equipment. For thece situations, considerably more information is required. Figures 18 and 17 are typical of forms used to collect alignment data for vtal equioment. * Identify the right hand side of the equipment train. With all alignment work, proper orientation is mandatory and must remain constant throughout the alignment procedure, Although either side of the equipment train could be designated as the right hand side, it has become conventional to make the identification by viewing the equipment tran from the driver-end, and this convention is recommenced. * Install the alignment brackets and dial indicators, Assure that the indicators ere in good working order (not sticking), that they are firmly secured to the brackets, that they are at mid-range, that the stems are reading on a clean, smooth surface, and that the stems are pointed directly at the shaft center After the brackets are installed and the dial indicators zeroed, shake the assembly to assure that itis tight and that the dial indicator reading returns to zero. if there ere Problems, fix them before taking any alignment data, ‘Additionally, slip a thin shim of known thickness or a piece of paper under the stem of each dial indicator. The indicator should register the thickness of the shim, and should retum ‘to zero when the shim Is removed, Rotate the entire assembly two or three times to assure that there is no interference, that the shafts tum freely, that the dial indicators have sufficient range euch that they do not “pattomn-out" or lose contact at any point during the revolution, and that they return to their initial values. Precaution: Dial indicators used in alignment work are always assumed to be direc-reading, i, that a positive reading is obtained when the indicator stem is pushed in. Also, pay particular attention to the markings on the indicator dial which may be elther continuous or balanced. A continuous cial on a direct-reading indicator starts at zero ‘and has continuously-increasing numbers in a clociwise direction. A balanced dial, on the other hand, starts at zero ‘and has continucusly-increasing numbers in both clrections. Page 14 Either type can be used, vigilance to assur ind both types require equal that proper readings are recorded, * Rotate the shaffs in the normal direction of rotation of the. equipment until one of the dial indicators is resting at top ed center (tdc). Zero the indicator. Continue to rotate the shafts precisely 90 decrees until the dial indicator horizontal. The reading wil be positive (+) ifthe indicator pointer has rotated clockwise during the 90 degree rotation; ‘twill be negative (.)if movement has been counterclockwise. Record the reading. Itis conventional to record the reading in mils (1 mil=0,001 in). Continue ‘otation until the dial indicator is at bottom dead center (bac), Record the reading. Continue rotation another 90 degrees until the dial indicator in horizontal on the second side of the machine train. Record the reading. Continue rotation unil the dial indicator is again at tde. Check to see that the dial Indicator retums to zero, Now rotate the assembly unti the second dial indicator is resting at tdc. Repeat the above procedure for the second indicater. Repeat the entire procedure a second time to assure accuracy and repeatability. It takes a short time to check the readings. It takes much longer to correct errors. + While itis not a requirement to start the readings at tc, It is normal to do so, and \d practice. Establishing a routine for taking data is an aid in securing consistent tesults, and starting at tdc is can be part of an established routine. + Please note that itis not essential that the dial indicators be zeroed at the start of readings since it is teadings vertically and horizontally that are important. Again, however, itis pert of an established routine and it is. ‘good practice to start at zero. + Depending upon the brackeis being used and the arrangement of the equipment, both dial indicators may or may not be at tdc simuttaneously. One may be at tde while the second is at bdc, or they may be arranged randomly. ‘The specific arrangement is of no concer so long as all readings include tde and bac positions. Regardless of the arrangemert, itis recommended that data from only one indicator be taken curing one complete revolution of the equipment. While data can be taken from both indicators during one revolution of the shafts, it is the experience of the author that this practice is very likely to lead to errors in recording the data. Fewer errors will result if ail data is taken from one dial indicator before taking any data from the second, Use care to assure that the shafts are stopped precisely at 90 degree increments. Four-point levels with a magnetic base are avallable for this specific purpose, and are a very worthwhile tool, + Watch the indicators continuously as the shafts are being rotated. Be sure to determine ifthe di Positive (+) or negative (-) direction, and be sure that the dial has not turned a full revolution without being detected,ROUTINE EQUIPMENT FACE & RIM ya{ VITAL EQUIPMENT Figure 14, Face & Rim Method data sheet for routine equipment. ROUTINE EQUIPMENT REVERSE-INDICATOR METHOD rain Figure 16. Face & Rim Methad data sheet for vital equipment YITALEQUIPMENT. ‘REVERSE INDICATOR METHOD Figure 15. Reverse Indicator Method data sheet for routine ‘equipment. Figure 17. Reverse Indicator Method data sheet for vital ‘equipment.+ Ifthe coupling spacer is removed (as with face & rim readings), it will be necessary to rotate both shafts independent while dial indicator readings are being taken, ‘end precautions must be taken to assure that both shafts ar rotated to the same relative position at each reading. Thi best done by marking the places at which the dial indicator ‘stems rest upon the equipment. Each time the shafts are rotated to another quadrant, these markings will assure that the shafts come to rest at the same relative position. Precaution: Use care when taking alignment data on machines equipped with tit pac journal bearings. Such bearings usually have en uneven number of pads (5 Is typical). Ifthe pad arrangement is such that one of the pads is on bottom dead center (load on pad}, then the shaft can rock horizontally, wthin bearing clearance, as the shafts are turned to get alignment data. it may be necessary to stabilize such bearings with temporary shims, or ty some ‘ther means, while alignment data is being taken. If the design is such that one pad is top dead center, then the problem does not exist. CHECKING AND CORRECTING READINGS Having recorded consistent dial Indicator readings, they must be checked for consistency and corrected for bracket sag. A typical set of dial indicator readings from a reverse indicator arrangement are shown at the top of Figure 18. The "R" in the circle reflects the reading taken on the right hand side of the equipment train. Readings are in mils. ‘= Step 4 - Check for consistency: For machines that are in relatively good alignment, a check for consistency can be made by summing the vertical readings (tdc plus bi ‘comparing that value to the sum of the horizontal r (left-hand plus right-hand reading). For the readings Machine A, the sum of the vertical readings is -28, as is the sum ofthe horizontal readings. For machine , the sum of the vertical readings is 8, as is the sum of the horizontal readings, The readings are consistent. This is @ simple, but a very important check. When the absolute values of the dial indicator readings are small (say 20 or less), good readings will “add-up" within 1 mil. As the Teadings become larger there is likely to be some deviation. Typically, however, the sum of the vertical and horizontal readings should deviate no more than about § percent of the largest single reading. if larger deviations exist, try to find the problem. © Step 2 - Correct for bracket sag: Bracket sag has a pronounced affect upon readings taken in a radial direction. When using the Reverse Indicator Method, this means that both sets of dial indicator reacings must be corrected. When using the Face & Rim Method, only the rim readings will be corrected. To correct for sag, merely add th bracket sag to the bottom dial indicator reading. For this ‘example, the bracket sag is 4 mils. The corrected readings are as shown in the center for of Figure 18. solute valve of the Page 15 * Stop 3 (Optional) - II readings positive or zero, ‘While this step is not mandatory, itis highly recommended, especially ifthe alignment of the equipments to be determined by manual plotting. For most persons, it is very much easier to deal with zeroes and positive numbers than to deal with a combination of positive and negative numbers. STEP 1: RECORD RAW READINGS AND CHECK FOR CONSISTENCY 0 Q “C= C3: -28 8 STEP 2: CORRECT FOR BRACKET SAG OF 0.004%, ADD 4 MILS TO EACH BOTTOM READING 0 0 C= 3 : -24 12 STEP _3 (OPTIONAL: FOR EASE OF PLOTTING, MAKE ALL READINGS ZERO OR A POSITIVE NUMBER 24 0 16 C : 0 12 Figure 18. Dielindicator data chock and corrections for bracket sag. To meke this correction, each set of vertical and horizontal numbers can be handled individually. For Machine A, add 24 to each of the vertical readings, making the bottom reading zero, and the top reading 24. Adé 22to the horizontal readings, making the right-hand reading zero, and 18. The vertical readings for Machine ready zero and positive, so no changes need be je. Horizontally at Machine B, deduct 2 from both readings, leaving a reading of 4 on the left-hand side, and zero on the right-hand side.“qwouudnbe eunros 10} ord Powe J0}ROIpU) es1eNeY ‘GE BuNDLY HES =| [Lathe ‘surtandu spd ova ong aon “sayojea moja au Je NOW UN cS. 1uee "UID nop 99 UM ON Yon “oom WHLOEIOY 8 brea) AoE + Lavirre ten 1S fase TASK, al aia! Et | [v2 4 ‘yes Keaoyoew oo ops puree ‘supoa sesadal un sa eetidnh sunnot 9} pavapeu09 00 “(avon su sone eas eu yo coneod yreoruoy oy) Oupuesaids om Ben09 « Tl raed roan eyes Vonncoe oven ok “pasn paucbe oD oe jes weed » (FUTZ (a1 ont.) ; uowdinba sunnow - Wewublry sore=IpUL aBenoN, sj i suoppnne Cuno"ywouidnbe euynos so} ed poysory wes 2 000-3 ‘Oz euntig su pon pu su eps ea ans vows 7uauiudye anced 9} pajoba: suoazancu AVN GA TY ON BE wy a x atone ey syd) aye Ko yuowidinby ougnoy - juowubyy wry pue ese suoyomvsu BUH“qweuidinbe re 40} jo1d poyjeW) Jo}eo|puy exseAcyy *4z en juowdynbs ex1q- }UEWUB|Ty 10,821PU| BsIBACY ‘uorPAUU CUEjuouidinbe joyn 40} or pompony wn @ 200.4 zz ounBis la] Teal Toety lee enS igo er | 1 i ez anti | : juowdinb fey ~ juowUBHy uN puE eed | ‘Svonrne Suet | aaa i LoessUSING THE RESULTS After the data has been collected, checked, and corrected for bracket sag, the results must be compared to the applicable alignment specification to see if alignment changes are required. Ifthe alignment criteria is very simple (maximum indicator readings, for example), determination of ‘acceptability is done merely by comparing readings to the specification. if other than very simple critoria is used, the ‘comparison may require calculations, plotting, or a computer routine, If the elignment is found to be acceptable, alignment tooling may be removed and the equipment made ready for service. After appropriate maintenance reports are ‘completed and fied, the job is finished. PLOTTING If the alignment fails to meet the acceptance criteria, the data can be used to determine how the machines must be ‘moved to bring them into compliance. This is best done by using a computer program, or by manval plotting. In reality, however, itis often done by tral and error ~ the most costly of all options. For this Tutorial, only the plotting option will be considered. Four examples are presented, along with detailed plotting instructions for each example. Figure 19 is a typical plot of routine equipment aligned by the Reverse Indicator Method. Figure 20 is a plot of the same equipment aligned by the Face and Rim method. Routine equipment is defined as equipment where thermal movement is considered in the vertical direction only, and ‘where such thermal movements are uniform along the length ofthe equipment, Figure 21 is a typical plot of Critical equipment aligned by the Reverse Indicator Method. Figure 22 is a plot of the ‘same equipment aligned by the Face and Rim Method, Critical equipment is defined as equipment where thermal movements in both vertical and horizortal planes are ‘considered, and where such movements are non-uniform along the length of the machines, Plots for critical ‘equipment typically are more complex than for routine equipment even though plotting procedures are essentially identical. Precaution’ When aligning equipmentto parallel-shat gears, itis important to recognize that gear forces will move both shatts to new locations within the bearings when power is applied. In most cases, these movements should be ‘considered when aligning the equipment. Simiarly, it may be important to con: within bearing clearances when al equipment, or equipment with very large bearing clearances. Ifthe equipment has non-contacting vibration probes, gap voltage can be most useful in determining journal movements within the bearing, Page 16 MOVING THE MACHINES Alignment changes, when required, are accomplished by adding or deleting shims, and/or by moving one ofthe Machines laterally until the desired cold alignments realized. Typically, this is a fairly straight-forward procedure if appropriate tools are on hand to accomplish the task. The following general suggestions are offered: * Check the dial indicator data and plots carefully before making any machine movements. t takes litle time to, check the data. It takes much more time to re-do improper moves. + fone of the required movements is significantly larger than the others, make the largest required movement first This single move will make a significant improvement in alignment of the equipment, and will improve the accuracy of subsequent alignment data sets. Ifno single required movement is much greater than the others, then make alignment corrections first at the supports furthest rom the ‘coupling. Since coupling alignment is less affected by the Position of the outbcard support, itis less likely thet Subsequent moves will be required at that location. It should be noted that some craftsmen prefer to make vertical movements before making horizontal movements. thers prefer to make horizontal movements before making vertical movements. In realty, it makes little difference, and the decision is best made on the basis of the greatest movernont required. * When making shim changes, loosen only the support where the change isto be made. Snug the boit down after the shim change. * When making lateral movements, itis normally good practice to leave one hold-down bolt tight, and to rotate the Tachine around that bot Typically, a dial indicator with a ‘magnetic base is used to monitor horizontal movements at the support location where the movements are being made ‘Some craftsmen, however, prefer to monitor horizontal movernents by using the dial indicators on the alignment, brackets. ‘A word of caution is appropriate at this point. The supports ‘on many machines, especially cn larger equipment, are relatively flexible laterally and may not move in unison; ‘when one support is moved laterally, the support on the opposite side of tho machine may move a lesser amount, or may not move at all. For such machines, itis necessary to monitor the movement of both supports as lateral movements are made. ‘* Important. Keep tabs on shaft separation as the alignment work progresses, Machines have a way of getting moved avially during the alicnment process and it is very difficult to make a final axial adjustment without adversely affecting radial alignment.‘® Make one move at a time, then re-check and update the dial indicator readings. Again, it normally takes much less time to check the date than to correct an improper move. * Consider the job completed when the alignment criteria has been met. inordinate amounts of unnecessary time and money can be wasted "trying to get things a lttle better’ ‘* Be wary of alignment moves that "do not go right". For Properiy-installed equipment, alignment moves ere very Predictable, ifthe equipment does not come into alignment {8s predicted, look for a problem such as pipe strain, casing distortion, improper shims, bolt-binding, stc. ‘* Make one last check of hold-down bolt torque after reper alignment is achieved. * Take a final set of dial indicator readings forthe files, and be sure that complete data is included; i.e., final dial dicator readings, right/left orientation identified, dimencione shown, plus any pertinent comments for the next person doing the job, Date the data sheet, sign i, and get it into the file! THE HOT CHECK As noted eartier, the ultimate objective of the alignment ‘exercise Is to assure that shatt alignment is acceptable under all operating (hot) conditions, and that the equipment wil ‘remain property aligned for an acceptable lenath of me. The Purpose of the hot check is to verify alignment in the running condition. Most authorities suggest that a hot elignment check should be done on virtually all vital equipment, on equipment of high horsepower and/or high speed, and on equipment operating at other than ambient temperatures. These ere probably valid suggestions. In practice, however, alignment checks are actually done on only a small percentage of machines. A recent telephone survey of engineers responsible for rotating equipment with a number of large companioe revealed the following: Predominately, hot checks are routinely conducted on the largest anc mest vital equipment such as centrifugal compressor trains, but are conducted on other equipment only if problem is evident. A few users Teport that hot checks are conducted only if vibration analyses indicate a problem, regardless of equipment size andlor criticality. Practices seem to have changed very litle aver the past two decades. In view of increasing pressures for higher reliability, longer run times, and reduced maintenance costs, itis surprising that routine het checks are nat more widely done. It would appear to be a fruitful area to pursue. The following are. common procedures, * Manufacturers Recommendations: For major equipment, itis common for the manufacturer to provide data concerning expected thermal growth. These data may be calculated, they may reflect experience from similar or Identical machines, or some combination of the two. These data are normally Used for initial machine installation. Page 17 Experience with manufacturers! data varies. If similar machines have been built and tested. if the machines are operated near design conditions, and if they are not unduly influenced by outside factors such as pipe strain, then the vendor data may be excellent. For some machines, however, vendor data does not approximate field measurements. For machines in vital applications, itis generally agreed ‘that vendor data shouid be verified by a hot check. Precaution: Be wary of thermal growth data thet is vague. If, for example, the data simply says that the discharge end ‘of a compressor is expected to grow vertically 0.012 in, and. there is no expected growth on the suction end, be very careful. To be useful, the data must say precisely where the growth is expected: i.e, at the coupling, at the machine ‘Supports, or at the equipment flange. Do not use vague data, * Calcultions: Thermal growth calculations are sometimes done on the basis of machine geometry and ‘measured or calculated metal temperatures, While such calculations are better than nothing, they are generally not Very reliable. Additionally, they do not account for external loads such as piping, which may be substantial, 1 ccalulations are used for intial installation, they should be Verified by a hot check. ‘© The Traditional Hot Check: The se-called traditional hot check involves running the equipment until thermal equllibrium is achieved, then shutting the machine down and ‘quickly taking alignment data with the same tools used to. align the equipment intially. It may or may not involve Temoving the coupiing Except in rare cases, the results of this type of hot check. have proved to be very poor. First, the procedure requires a machine shutdown which is often costly and unpopular with operating personnel. Secondly, the equipment cools down very quickly after shutdown, as does any connecting piping. Hydraulic affects, if any, are lost immediately. Moreover, it is virtually impossible to take readings quickly enough to, assure that they are meaningful, and data simply cannot be verified because the machines are moving during the exercise. An additional concem is personnel safety. If the ichines are very hot, it is questionable that people should be asked to work on them, * On-Line Methods: Because of the shortcomings of the methods mentioned above, a number of on-line hat check methods have been developed. Figures 23 through 28 are conceptual depictions of these various methods, all of which are fleld-proven, While details of the various methods are beyond the scope of this Tutorial, appropriate material is noted in the reference section. Additionally, many of the manufacturers and vendors of this equipment, as well as those providing alignment services, are among the exhibitors at the Symposium. ‘While all of these methods can provide reliable on-line alignment data, they vary greatly in cost, complexity, and. ase of use, Moreover, none of the methods are applicable to every situation, No attempt is made to providecomparative data. The user is urged to review the merits of each system, and to choose the system that best fits the need. Precaution: With the exception of instrumented couplings, all of the methods listed below use cold coupling alignment readings as baseline from which to calculate (or plot) hot coupling alignment. its vital, therefore, whatever method Is used, that the "cold" baseline data be taken at the same time the cold coupling alignment data is taken. Reliable results simply cannot be obtained by taking coupling data in the cool of the morning, for example, and hot alignment baseline data in the blazing afternoon sunshine, Take the data simultaneously. + Optical methods: Optical methods (Figure 23) employ very precise surveying techniques to determine machine movements, from which shaft alignment information can be ascertained, To use this method, coupling alignment is done in a conventional manner after which vertical and horzontal vaseline data is obtained with precision levels and transits. When the equipment is put on line and brought to equilibrium, this same optical instrumentation is used to determine the movement of each of the machines with respectto the baseline data. From these data, running alignment can be plotted or calculated. COLD ALIGHMENT If THE BENCHMARK. + HOVENENT REFERENCED TO LINE. OF Sich + OPTICAL LEVELS éND JIG TRANSITS USED 10. DETERMINE. VERTICAL AND) HORIZaNTAL MACHINE FIVEMENTS Figure 23, Hot check by optical means. While some companies employ in-house specialists to conduct hot alignment checks by optical methods, it is more ‘common to use one of the several commercial firms who offer these services. + Lasers; Several variations of laser monitoring (Figure 24) are available. Typically, machines are aligned ina conventional manner, and a laserireflector system is used to monitor the movement of one machine casing with respect to = COLD ALIGNMENT IS THE BENOWARC @ LASER SYSTEN USED To MONITOR RELATIVE MACHINE MOVEMENTS “e DATA ANALYZED/RECORDED BY COMPUTER SYSTEM ©) [nes ey Figure 24. Hot check by leser systems. Page 18 the adjacent casing. From this data, coupling alignment can be determined by plotting or calculations. In some systems, the laser equipment is mounted permanently upon the equlpment. In other systems, brackets are used to permit the lasers to be installed andior removed during operation. + Proximity probes with water-cooled stands: With this method (Figure 25), water-cooled stands are affixed to the foundation near couplings and outboard bearing housings. These stands are used to support electronic proximity probes Which monitor the movement of the coupling, shatts, and/or machine casings relative to the foundation. © COLD ALIGNWENT 15 THE BENCHWARK ‘* MACHINE MOVEMENTS REFERENCED | TO UATER-CODLED STANDS Log, © PROXIMITY PROBES DETECT MACHINE MOVEMENTS. DATA Is MONITORED ‘AND/OR RECORDED Figure 26. Hot check by water-cooled stands and proximity probes. ‘With this method, coupling alignment is done ina conventional manner at which time beseline proximity probe readings are taken. Equipment movements ere monitored Via these probes as the equipment Is brought on line and comes to equilibrium, and they may be recorded. Movement of the equipment relative to the proximity probes provides data from which to determine running alignment of the equipment. + Dynalign (Dodd) Bers: This is a method (Figure 26) of continuous, on-line monitering, using proximity probes that are fastened to permanently-mounted brackets on the coupled machines, The brackets are arranged in a fashi similar to that of indicator brackets used in the Reverse Alignment Method. Vertical and horizontal data from four probes supply information concerning the relative movement of the machine casings. © COLD ALIGNMENT 15 THE BENCHMARK RELATIVE MACMINE MOVEMENTS REFERCNCED Ta BARS AFFIXED TO Geposite WacIne ‘© PROXIMITY PROBES DETECT MACHINE MOVEMENTS. gata IS MONCTORED ANI/O® RECORDED Figure 26. Hot check by Dynatign (Dodd) bars. With this method, cold alignment is done in the normal manner and baseline data is secured from the probes. (Output from the probes can then be monitored and/ortecorded. Data is sufficient to plot, calculcto, or display running alignment of the equipment. + Benchmark Gauges: This eystem (Figure 27) monitors ‘the movement of bearing housings or machine casings with Tespect to the equipment foundation. To use this system, permanent benchmarks are mounted en the equipment and the foundation. Upon alignment of the equipment in @ conventional manner, benchmark gauges are used to determine baseline measurements between the foundation-mounted benchmarks and those mounted on the equipment. When the machines are brought on line, benchmark gauge readings are again taken to determine the felative movernent of the equipment. © COLD ALIGNMENT IS THE BENCHMARK + WACHINE voveMenTs REFERE: TO FOUNDATION'S REFERENCED ‘HOVEWENTS MEASURED BY DIGITAL ELECTRON ‘Behe? Gace © ALIGNWENT ANALYZED BY PC PROGRAM Figure 27. Hot check by benchmark geuges. Running alignment of the coupling is normally calculated by 2 PC program, but can be determined by araphical methods, also. + Instrumented Couplings: With this system (Figure 28), electronic probes are built into the coupling spacer. Power is ‘supplied to the probes vie a stationary transformer, and signals from the probes are retrieved in a similar manner. This arrangement provides on-line, continuous monitoring of coupling alignment as well as axial movement of the coupled shafts. © BASE DATA TS BY COUPLING ALTERATION © PROXMITY PROBES WITHIN THE COUPLING DETECT MISALIGNMENT * SIGNALS AND POVER TRANSMITTED BY STATIONARY TRANSFORMER Figure 28 Hot check by instrumented coupings. CONCLUSION Satisfactory and long-lasting alignment is achieved by paying atiention to details throughout the design, fabrication, and installation of the equipment. Toward this end, the following are minimal requirements: + Rotating equipment that is properly designed and well made, Page 19 ~ Awell-designed and properly-executed system into which ‘the equipment is integrated. + Knowledgeable, careful, and experienced craftsmen, + Proper training of both craftsmen and superviscry personnel, + Appropriete tools. + Standards and/or specifications detailing alignment requirements, + Asystem to assure that job specifications are followed. ACKNOWLEDGMENT The Author gratefuily acknowledges the generous contributions of the many craftsmen, craft foremen, factory ‘service personnel, mechanical inspectors, engineer's, and ‘thers who have shared the'r alignment experiences and expertise over many years. My personal thanks to each of you, Hopefully, the material in this paper represents you well BIBLIOGRAPHY Campbell, A.J., "Optical Alignment Savee Equipment. Downtime," Oil & Gas Journal (November 1975). Campbell, A. J.,"The Laser - As Used in Alignment,” Proceedings of the Ninth Turbomachinery Symposiim, Gas ‘Turbine Laboratories, Texas A&M University, College Station, Texas (1980), Dodd, V. R., Total Alignment, Tulsa, Okiahoma: Petroleum Publishing (1975). Dodd, V. R., "Total Alignment Can Reduce Maintenance and Increase Reliabilty’, Proceedings of the Ninth Turbomachinery Symposium, Gas Turbine Laboratories, Texas A&M Universiy, College Station, Texas (1980). Essinger, J. N., “Hot Alignment Too Complicated?,” Hydrocarbon Processing (January 1974). Essinger, J. N., "Benchmark Gauges for Hot Alignment of ‘Turbomachinery," Procesdings of the Ninth Tursomachinery ‘Symposium, Gas Turbine Laboratories, Texas A&M University, College Station, Texas (1980). Finn, A. E., "instrumented Couplings: The What, The Why and The How... ," Proceedings of the Ninth Turbomachinery ‘Symposium. Gas Turbine Laboratories, Texas A&M University, College Station, Texas (1980), Jackson, Charles, "Reverse indicator Method of Alignmont,* Proceedings of the Sacond International Pump Symposium, ‘Turbomachinery Laboratory, Department of Mechanical Engineering, Texas ASM University, College Station, Texas (19885).Jackson, Charles, “Alignment Using Water Stands and Eddy Current Proximity Probes," Proceedings of the Ninth Turbomachinery Symposium, Gas Turbine Laboratories, Texas A&M University, College Station, Texas (1980). Massey, C. R., and Campbell, A. J., "Reverse Alignment — Understanding Centerline Measurements", Proceedings of the 218t Tursomachinery Symposium, Department of Mechanical Engineering, Texas A&M University, College Station, Texas (1892). Murray, M. G., Jp, "Reverse-Indicator Alignment and Related Subjects." Proceedings of the Ninth Turbomachinery ‘Symposium, Gas Turbine Laboratories, Texas A&M University, College Station, Texas (1980). Piotrowski, John, Shaft Alignment Handbook, New York, N. Y.: Marcel Dakker, Inc. (1988) Appendix A (Opposite Column) The following is the listing of a computer program for calculating shaf-to-spacer alignment using Face & Rim or Reverse Indicator Methods. The program was written using Microsoft® QuickBASIC 4.0. Before using this program, the user is cautioned to determine the suitability for his or her specific epplication. Appendix 8 The following is a sample printout from the Basic Language rogram shown in Appendix A ALIGNMENT RECORD FOR 8-772 ‘ALIGNMENT METHOD: REVERSE INDICATOR READINGS ON THE BLOVER (MILS: Top 9, gen ig BOrTOH LEFT READINGS ON THE MOTOR (WILS): gus 6 hits ELEMENTS: 10 INCHES His wits THE maxim coun 1 NT 1S AT FUECtOLEMatERNT MEAL TRGRTonS AT THE 44g MILS DER INCN OF COUPLING LENcTH 0:88 BeaREE WOT ALIoMENT: THE WAXIMUM HOT MISALIGNMENT IS AT THE FLEXIBLE ELEMENT NEAR THE MOTOR 37s ILS PER INCH OF COUPLING LENGTH Sc8ls WUE COMMENTS: ALIGNMENT AFTER MOTOR CHANGEOUT DATE: 10-14-94 vn Cis" coun, @. cos OCATE 4 20 Prov “M4 PRocnaM CALCULATES meALicuMenT O° LOCATE, 20 PRO “THE COUPLNG SPAGEN WITH RESPECT TO THE” LOCATE, 24 PRINT “SHAFTS OF THE COUPLED NACHNES™ LOCATE, 33 Prat “OPTIONS ARE" PRINT THE BRACKETIS FASTENED To: LOcaTe4 37 COLOR? PRAT pans = LODATE, 37 PRINT Ag: PUNT: LOCATE 4, 9 PRAT” spre PRNT™ THE DALINDCATERS READ ON: Pun, moToR, Ero)* ‘98.COLOR 7: Pat = PRNT:PRINT: PRN” THERMAL GROWTH. OF TEAS“ COLOR. 8 INT= MSs FACE DAMETER AT WHICHINOICATOR, : PRN" READINGS ARE TAKEN IFFLAGI= 1 THEN SAG = GAG" 1000: LAGI = ocaTEl2a & PRINT-THE SAG OF THE NOCATOR BRACKETS" SAG:"MLS RIT: PANT Pan” 0 YOU WaT Guan ANT GF TH DATA COLon 7 PAR ORI)T COLOR cece, KSe—Ks= macys FLAGS = 1 618: PANT: PRAT: PRINT LOCATE 4 2: PRINT INPUT DAL ROCATOR RM READAGS ALS PRICT Locate @ S neut= Ton’ Atom: eu “Atom osuD Lenco LOCATE 7 $2 NPUT~ RIGHT ARGHT TEN® = AUGHT GOSUB MLCHECK LOCATE a $2 NEUT* BDTTeM= ABOTTOML TEMP = ASDTreur CDEUG MiLCHECK LOCATE 0 32 NPUT= DIALCHEDK = ATOR + ABOTTON) - (RIGHT + ALE IRASSIDALCHECI «13 MeNGoID CHANGE LOCATE 1, 1S: PRINT “CAUTION. il READINGS DO NOTADOUP= LOCATE 12, 1S/PRINT= "Top Puve Barrow SHOULD COUAL OMT PLUS LET UGcaTe 1s, 1s:prir oo You wsH1To CHANGETHE READS (COLOR 1,7: PRINT"(7 ORNI7™ COLOR 7,8 creas:KS = kgs nes, IRs “rTwen cbs; coro RuncADtiCg Fig" THENG.S: coro namesoncs TE RS= "y-THEN GOTO FACEREAONGS Goro chen FACEREADNGS: FLAGS = 1:CL.5: LOCATE 421: PRINT TNPUT DAL INDICATOR FACE READNGS QMS) [email protected]:meUT? TO? FACTOR. TENE = FACETOP: COSUS MILCHECK Lome 7.32 NUT: RENT” FACERIGTT LOCATE 9 S2:NOUT" _LEET® FACELEFT TEMP = ACELEFT.coeue Ma.cucoK TORE: FAGETP: Rohs PAGERIGHT: BOTTOM? = PACESOTTONE LEFTY = FAGCLEFT, Fags PRINT: DALCHECK = FACETOP + FACEBOTTOM - FACERIGHT+ FACELE) FP ABsDALGHE «1.2 HENCOTOCHANGES LOCATE, 1 PRINT “CAUTION: FACE REAQINGS DO NOT ADO UP LOGATE 12,16 print= Top Puls BoTToN SHCULD EGUAL RIGHT PLUS LEFT PRN Chances LOCATE 15. 18: pen D0 You wisi ToCHANGE Mee READS > COLOR, PRINT tr Om M7 COLOR 7, © cco Gen ks= mers REVERSENOOATA: Coven 7. ccs) PRAT Pan (GENERAL DATA FOR THE REVERSE NOICATOR METHOD = PRNT:PRNT" ONE COUPLED MACHINES ISTHE UMP, NoTOR, ETE) * LOCATE «34: PUT" AS IGEATE 4 34 60LOn 7,9: Praar= : LOCATE 434: PRINT AS: PRINT" LOCATE 41: PRINT" J Pret PRINT” THE OTHER COLELED MACHINES THE tOcaTes 52 COLORS, PRINT SN IOCATE 6 30: REUT™, Bs WecaTEa se coLoniermnr = LOCATE 6, 3: PRINT BS: PRNT:LOCATE 6 52 PRINT" : PRINT: PRAT: RINT” THERMAL GROWTH OF THES AS. "1S IDeaTeo. 4 covons,7 ants" = eeten (eum, Moro, ere)* “THERMAL GROWIM OF THES ABI \DEATES 45: COLORT, @ PRINTAGROWT= MMS = PRINT: PRIMT™ THERMAL GROWTHOF THE 85;"1 (Beate as: coLoe 3, mms ‘COLORT,O:PRAT" MLS LOCATE 11.45: COLOR %. WeUT = saRowmt eaten 7, TeMe « eoiowin: cosa MiLcreex IFFLAGI = | THEN BGROWTH = BGROWTH' tom> FLAG =o LOCATE 11,6 PRINT TMERUAL GROWTH CF THE BIS LOCATE 11:48: COLORT, @:PRATBCROWT" MES = LOCATE 13,6: PRATT THE CISTANCE BETWEEN THE PLANES WHERETHE LSGATE 1418. PRNT“DAL NOCATOR REAGINGS ARETANEN 6 PREMES)-| LOCATE 14/48" COLOR f 7:PRINT™ = CCLOR TD LOCATE 1448 COLOR 1 7: put —, ecsAtamen! COLOR 7, LOCATE 14,8 PRAT "DAL NOICATOR REAONGS ARETAREN IS > LOCATE 10.2 PRITHE DSTANCE BETWEEN THER DOLEREMETS + LOCATE 17 & PRN Ue THe COOPLAOISS Soon bene LOCATE 19, PRNTT"THE SAG OF THEINOKCATOR BRACKET 1S COLOR. 7 oR IFAAG!= 1 THENSAG= SAG" 1000: RAGI=0 CATE 19, € PROT “TE SAG OF THENIOCATOR BRACKETISSAG"MRS = nvr: Prat: Prave= D0 YOUW/SH TO CHANGE AY OF THS DATA ‘COLOR , 7: PRINT-TY CR N)T: COLOR T, 9 cece ioe igs 3 They caro pevensenconra = THEN GoTO REVERSENOOA Fig = THEN GOTO HEVENSEN (FNS = THEN GOTO REVERSEA sora cHecxs Revesek: LAGU CLS: LOCATE 4 28: PRT INPUT READINGS FROMTHE DAL* LOCATE § 28 PANT MOCATOR NEAREST THES AS LOGATE 31: mePUT- Tor” Aor: Tene = ATOP-GOSUR MALGHECK LOCATE NG 31: NPUT" RIGHT” ARGHT TEN = ARIGHT: GOSUE MLGHECK WOCATE 31: NPUT= BOTTOM” AooTrON TeMe= ASSTTeaL GosuoNm HECK LOCATE 12.31: NPUT* | LerT™, ALERT: TEMP ALEFT:COGUa MLGHECE Toet= Atom RUNTY = aplout borToMt= asorTou Larry © AUST Ponce cence TEAUTION: READINGS Oo NOT ADOUP.= LOCATE 16 15:PRINT" TOP PLUS BCTTON SHOJLO EQUAL RIGHT PLUS LEFT” SGCATE 7, 16: prnet= 50.YoU WISH TO CHANGE THE READINGS [COLGR 1,7 PRINT "1 OR 7 COLOR 7,8 LOCATE S36 PanvT INOCATORS NEAREST TES BF "Top" BoP Tews = FTG cosa MLcuccx LOCATE, 30: NPUT*_RGHT® BRIGHT: TEMP= BRGHT. GOSUS MLCHECK LOCATE 16 80: NPUT BOTTOM” GGOTIOM TEM= BSTTCM: GOSUE MILCHECK. SGEATE 1, 90: PUT “Lert SLerT TEMP" BLP: GOUUR MICCHESR ‘TOPs STOP: RIGHT2 = BRIGHT: BOTTOMa= BEDTTOM LEPT2 = BLEFT: LAGS = DiALweox- (stor + BocrToM = (aur = EH FABSDIALCHED «1.5 THEN GOTOCHANCES LOCATE 1418: peivT “CAUTION: REAMES bo NOT ADDU. : NOCATE 1S 15:PRIETT* TOP PLUS BOTTOM SHOULO EQUAL RIGHT PLUS LEFT* chansee: LOCATE 17 18: _D0-you Wist TOCHANGE THE READINGS COLOR, FPR" OR NTS COLOR 8 ese -mcers Bigs ‘t netro mevenses REM EQUVALENTS CALCULATES ECLIVALENT WAL READINGS FOR THE REVERSE [REM NOICATOR METHOD WHERE THE SPACER MAY BE A DFAT LENGTH ERM REM THE MOICATOR SEPARATION Eauiwenrs: [APs ATOP: A ~ ARGH: AS = ABOTTON AL = ALERT {Br = BrP: BR = BRIGHT 83 = BBOTTON B= LEFT AS (AT-AB\/2: 8 = (8-5/5 SP. D= SEPARATON =O. 9/2 F=0-CGeA-BH=G'E/D I= BeH KoG-e/orusa en ASOTTOM #0: ATOP #2": TOP = @/SBCTTOM= 2*L Ar MS-As/2 b= @.-0n/2a=A-8H=G* F/O; J=8+H Krarerm tea (NEFT #0: AUGHT=2° BRIGHT = O:BLERT=2°L couporrser: REM: ACOLD AND BCCLD ARE THE TOTAL ANGULAR OFFSETS O= Tus COUPLINGS AT BEM MACINES | AB RESPECTIVE, ML ea ReM or CUS LECT coin: = ABOTTOND 3.42 WARGHT- LEST 12 5 ‘ACOLDs (((BTOP- BBOTTOM)/3) 92 (SHIGE SLE 3°) * SP REM: BANGCOLD'S THE COLD ANGULAR OFFSET AT MACHINE 8 DEGREES REM: AANGCOLD'S ThE COLD ANGULAR OFFSET AT NAGHINE & DEGREES ‘BknceouD = Beato os7=88 ‘AANGCOLD = ACOLD * 057208 REM AD0S THERMAL GROWTH TO CALCULATINS FOR HOT ALGNMENT CALCULATIONS 2+ AGROWTH. GROWTH)[MOT = (STOR BOTTOM /2)*2 + (BRIGHT -BLEFD /3.*2)4 519° ext AANGHOT's THE HOT ANGULAR OFFSET AT MACHINE A CEGREES Axor: REM SELECT THE MA.OR MISALIGNMENT I THE COLD ConoMMON. IFACOLD == GCCLD THEN HACOLD = ACOLD. COLDS =A COLDANG = MAXCOLD * ‘sree FGceto >= ACCLO THEN MAXCOLD = COLD: COLDS =: COLDANG = NAXCOLD + a) REM SELECT THE MA.OR MISALIGNMENT I THE ANCT CONOTON IFANOr == HOT MEN MAGIOT= ANDY MOTE = AB" HOTANG = WASIOT*.057208 TEGHOT >= AHOTTHEN MAIHOT = HOT. HOTS «BS: HOTANG = WAXSGT © 057356 (CLS: LOCATE 4,17: PRINT “COLD: THE MAXIMUM COLD MISALIGNMENT ISAT THE? LOCATES, 8 PRAT” FLEXBLE ELEMENT NEAR THE COLDS {LOCATE 7,23 PRAT USING"ey a WIS PERINCH OF COUBUNG LENGTH, MAXCOLD LOCATE 8, 3: PRAT USING "s ses DEGREES™ COLDANG: PRINT LGCATE 10, fe Pen HOT THE MAXMUM HOT MMSAUGRMENTIS ATTHE CCATE 1-18 PANT” FLBUGE ELEMENT REAR THE HOME Pn LOCATE 13°25: BRINT USN Sees We Fak NCH CF ECUSLNE LINEN, MAQIOT LOCATE 14 2s: PRNT USING “a a8 CEGREES" HOTANG LOCATE 16,24: PanT-OPTONS ARE" LOCATE 18, 2¢ PRINT) PRINT A COPY OF THE RESULTS" LOCATE 19,26 PRINT“ OO ANOTHER CALCULATION LOCATE 20; 2¢ PRINT 3} QUIT THE PROGRANE LOCATE 22:26 COLOR, ZPRINT= SELECT OPTION 1, 2,08 3 ~ COLOR7, 8 CREO Ks = RMEYS Fag = HEN COTOMEN xs = THEN COTOGUT Goro chee PaNToUT. CLS: LOCATE 4,20: PRINT “EOUIPMENT TRAN ICENTICATON" focare's ss couore 7 pat LocATE 55: INPUT™ TRANS EeGATE 4 68 eouon © PRRTTRAME,:PRnT= LocAaTE@ 29 PRNT-DATES LOCATE 8: 27. COLOR 7: FANT Locate 27 NeUT™ DATs LGGATES, 37 COLOR, PRNTOATE :PRNT= LOCATE 8, 2: PRA -COMMENTE COLOR 1,7 ETPES = “rR THEN LPPUNT THE ALCNMENT BRACKET ISON THE AS IETYPEs = FR THEN RINT. {E TYPed = Sp THEN LDRINT "DUAL NOCATOR READINGS ARE TAKENON THES 08 EE Types = FE THEN LORINT “THE Ri READINGS ARE AS FOLLOWS (MLS} = IE Types =F THEN LERIN READINGS ONTHES A3:° OMS)” LPRNT? TORS; TOPY Cent? lon Reem tear porto ecriow tennt> “terrae tem SEoyecs «Fe HEN Loman “THE FACE READINGS ARE Ae FOLLOWS (ML) fF Typed = Re THEN LPRINT READINGS ON THE 5 B8:" Dm} tone UpRNT* Tors ToP2 Upnnt> gore Renna Upant= sorrodssorroN2 tear errs bers {pret THerWAL GROWTH OFA TAR; AGRON MLS pain ThacavAL GROWTH OF = BS TABS; BOAOWT “WL LRNET {IE TYPER= "AE THEN LPRINT TABQ; SEPARATION, NOES” LUPRINT NOICATOR BRACKET SAG" TASS) SAG,"MSS PRINT: LPRINT UpRINT “COLD AUGNMENT= Lenn: Pan pranr= “THe MAOMUM COLD MSALGNVENT 5 ATTHE” UPRNT™ RIBOSE ELEMENT NEAR THE COLDS RINT LPanT UeNe* wnamn MLD Pom Wt oF COUPLNG LENGTH MAXCOLD PRINT USING” swe OEGREES ,COLDANG: LPRINT (eran HOF ALGRQMENT™ CPR opine MARIA RET MEALGHMENT SAT THE™ Lerinr= | FLENIBLEELENENT NEAR THE™ HOTS LPRINT Lek Usa" en Ws PER NCH OF COUPLING LENGTH MASHOT rn Usa = aan DEGREES FOTANG {Bru : CesT: LeRNT “COMMENT: COMMENTS Lene: LPR: CPRNT: PRINT (ean -DaTe Soars" GS" GOTO ANSWERS SPACERTEST: (eater runs ©" WARtNG! Ts PROGRAM IS FOR SPACER TYPE COUPLINGS ONLY FRunt= KNOWL USE 2 INCHES AS THE WNMAJM SOACER LENGTH. Pant Tie lenoTa Vato Assuwrnion ronvouR APPOCATION, THN Frat DONCTUSE'THE PROGRAM (PRESS ANY KEY TO CONTI)” rest AS aPKerS FLewas) <1 TEN Goro TEST: (eaten Bene Sra BV MITA LPR CHE) wcrc IFABSITEME) > 400 THEN FLAG! = 0: RETURN Frin™ WARANG! TMS ENTRY MUST BEN MLS -NOTINCHES. THERMAL cROWTH? rt- "SAG, ANG OAL ROISATOR READINGS MUST SC ENTENEDIN MRSS insTRUCTIONS: ane MeALGHOMENT CALCULATIONS ant ASSUMPTIONS ANO GEFATIONS = LPR .couPteD YANGULARTY 5 DISPLAYED pres lenin ca de tee Gare Na Bue erent 2 ENGUSH UNTS ARE USED, NCHES FOR LPR MACHINE DMERSONS, AND MLS AL=0201 9 FORCAL* Uenin~ me uueseat AT oom ENS OF MEMAGHINE. THERMAL: LPRINT® GROWTH UPWARD ig POSTIVE: DOWNWARD Is NECATIVE™ LPRINT LUbaint4)"tae COUPUNG SPACER GATLEAGT? MCLE LONG. FTE PRINT” USER ENTERS A SPACER LENGTH OF LESS THAN 2 NCHES, A WARNING" LpruNT= Is DISPLAYED. AND ANY FUTHER CALCULATIONS ARE DONE ON THE” Upivt=_ BASIS OF Az New SPACER” LENT pnt" TH To POSITION TO INE BOTTOM POSTION AS CHECKED ONA = LPRINT? MANOREL. ALTHOUGH THE DIAL NDICATOR IN SUCH A CHECK WILL” {PRs OAL NOATOR READIN ARE.CHECKEDFOR CONSISTENCY: LE.” LERUNT” "TO SEE THAT TOP+BOTTONLEFT*REGHT, THE READINGS ARE” Uren NOT CONSISTENT WTHIN 13-MLS AWARNNG © GNENS LUPRINT: LPRINT LPN “ASSUMPTIONS FOR THE FACE AND RIM METHOD LPRINT