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Formostrotatingmachinesusedintheprocessindustries,thetrendis
towardhigherspeeds,higherhorsepowerspermachine,andless
sparing.Thefirstofthesefactorsincreasestheneedforprecise
balancingandalignment.Thisisnecessarytominimizevibrationand
prematurewearofbearings,couplings,andshaftseals.Thelattertwo
factorsincreasetheeconomicimportanceofhighmachinereliability,
whichisdirectlydependentonminimizingprematurewearand
breakdownofkeycomponents.
Balancing,deservedly,haslongreceivedattentionfrommachinery
manufacturersandusersasawaytominimizevibrationandwear.
Manyshopandfieldbalancingmachines,instruments,andmethods
havebecomeavailableovertheyears.Alignment,whichisequally
important,hasreceivedproportionatelylessnoticethanitsimportance
justifies.Anykindofalignment,evenstraightedgealignment,isbetter
thannoalignmentatall.Precise,twoindicatoralignmentisbetterthan
roughalignment,particularlyformachines3600RPMandhigher.It
cangivegreatlyimprovedbearingandseallife,lowervibration,and
betteroverallreliability.Itdoestakelonger,however,especiallythe
firsttimeitisdonetoaparticularmachine,orwhendoneby
inexperiencedpersonnel.Theprocessoperatorsandmechanical
supervisorsmustbemadeawareofthistimerequirement.Ifthey
insistonhavingthejobdoneinahurry.theyshoulddosowithfull
knowledgeofthelikelihoodofpooralignmentandreducedmachine
reliability.Figure51showsaseriousmachineryfailurewhichstarted
withpipinginducedmisalignment,progressedtocouplingdistress,
bearingfailure,andfinally,totalwreck.
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PrealignmentRequirements
Themostimportantrequirementistohavesomeonewhoknowswhathe
isdoing,andcaresenoughtodoitright.Continuityisanotherimportant
factor.Evenwithgoodpeople,frequentmovementfromlocationto
locationcancauseneglectofthingssuchastoolingcompletenessand
prealignmentrequirements.
Thesayingthatyoucantmakeasilkpurseoutofasowsearalso
appliestomachineryalignment.Beforeundertakinganalignmentjob,it
isprudenttocheckforotherdeficiencieswhichwouldlargelynullifythe
benefitsorpreventtheattainmentandretentionofgoodalignment.Here
isalistofsuchitemsandquestionstoaskoneself:FoundationAdequate
sizeandgoodcondition?Aruleofthumbcallsforconcreteweightequal
tothreetimesmachineweightforrotatingmachines,andfivetimesfor
reciprocatingmachines.GroutSuitablematerial,goodcondition,withno
voidsremainingbeneathbaseplate?Tappingwithasmallhammercan
detecthollowspots,whichcanthenbefilledbyepoxyinjectionorother
means.Thisisalotoftrouble,though,andoftenisnotnecessaryifthe
lackofgroutisnotcausingvibrationoralignmentdrift.
BaseplateDesignedforadequaterigidity?Machinemountingpadslevel,
flat,parallel,coplanar,clean?Checkwithstraightedgeandfeelergauge.
Dothisuponreceiptofnewpumps,tomakeshopcorrectionpossible
andmaybecollectthecostfromthepumpmanufacturer.Shimsclean,of
adequatethickness,andofcorrosionandcrushresistantmaterial?If
commercialprecutshimsareused,checkforactualversusmarked
thicknessestoavoidasoftfootcondition.Machineholddownboltsof
adequatesize,withclearancetopermitalignmentcorrectivemovement?
Padheightleavingatleast2in.jackingclearancebeneathcenterateach
endofmachineelementtobeadjustedforalignment?Ifjackscrewsare
required,aretheymountedwithlegssufficientlyrigidtoavoiddeflection?
Aretheymadeoftype316stainlesssteel,orothersuitablematerial,to
resistfieldcorrosion?Wateroroilcooledorheatedpedestalsareusually
unnecessary,butcaninsomecasesbeusedforonstreamalignment
thermalcompensation.
measureflangegaparoundcircumference,thencalculateasfollows:
Gasket0.D.IFlangeO.D.I=l/8in.+(Max.GapMin.Gap)Maximum
ThicknessofTaperedFillerPiece1/8in.=DutchmanMinimumThickness
(180fromMaximumThickness).DutchmanODandIDsameasgasket
ODandID.
Spiralwoundgasketsmaybehelpful,inadditiontoorinsteadofa
taperedfillerpiece.Excessiveparalleloffsetatthemachineflange
connectioncannotbecuredwithafillerpiece.Itmaybepossibleto
absorbitbyoffsettingseveralsuccessivejointsslightly,takingadvantage
ofclearancebetweenflangeboltsandtheirholes.Ifexcessiveoffset
remains,thepipingshouldbebenttoachievebetterfit.Forthe
stationarymachine
element,thepipingmaybeconnectedeitherbeforeorafterthe
alignmentisdoneprovidedtheforegoingprecautionsaretaken,and
finalalignmentremainswithinacceptabletolerances.Insomecases,
pipeexpansionormovementmaycausemachinemovementleading
tomisalignmentandincreasedvibration.Betterpipesupportsor
stabilizersmaybeneededinsuchsituations.Attimesitmaybe
necessarytoadjustthesecomponentswiththemachinerunning,thus
aligningthemachinetogetminimumvibration.Sometimes,changing
toamoretoleranttypeofcoupling,suchaselastomeric,mayhelp.
CouplingSomeauthoritiesrecommendinstallationontypicalpumps
Installationanddriverswithaninterferencefit,upto.OW5in.perin.of
shaftdiameter.Inourexperience,thiscangiveproblemsin
subsequentremovaloraxialadjustment.Ifaninterferencefitistobe
used,wepreferalightonesay.OOO3in.to.OOO5in.overall,
regardlessofdiameter.Forthemajorityofmachinesoperatingat3600
RPMandbelow,youcaninstallcouplingswith.0005in.overall
diametralclearance,usingasetscrewoverthekeyway.Forhydraulic
dilationcouplingsandothernonpumporspecialcategories,see
manufacturersrecommendationsorappropriatesectionofthistext.
Manytimes,highperformancecouplingsrequireinterferencefitsas
highas.0025in.perin.ofshaftdiameter.
Couplingcleanliness,andforsometypes,lubrication,areimportant
andshouldbeconsidered.Sendingarepairedmachinetothefield
withitslubricatedcouplinghalfunprotected,inviteslubricant
contamination,rusting,dirtaccumulation,andprematurefailure.
Lubricantshouldbechosenfromamongthoserecommendedbythe
couplingmanufacturerorareputableoilcompany.Continuousrunning
beyondtwoyearsisinadvisablewithoutinspectingagreaselubricated
coupling,sincethecentrifugingeffectsarelikelytocausecakingand
lossoflubricity.Certainlubricants,e.g.,AmocoandKopperscoupling
greases,arereportedtoeliminatethisproblem,butvisualexternal
inspectionisstilladvisabletodetectleakage.Continuouslube
couplingsaresubjecttosimilarproblems,althoughsuchremediesas
antisludgeholescanbeusedtoallowlongerrunsathigherspeeds.
Byfarthebestremedyiscleanoil,becauseevensmallamountsof
waterwillpromotesludgeformation.Spacerlengthcanbeimportant,
sinceparallelmisalignmentaccommodationisdirectlyproportionalto
suchlength.
AlignmentTolerances
Beforedoinganalignmentjob,wemusthavetolerancestowork
toward.Otherwise,wewillnotknowwhentostop.Onetypeof
tolerancemakestimethedeterminingfactor,especiallyona
machinethatiscriticaltoplantoperation,perhapstheonlyoneofits
kind.Theoperationssuperintendentmayonlybeinterestedingetting
themachinebackontheline,fast.Ifhisinfluenceissufficient,thejob
maybehurriedanddonetoratherloosealignmenttolerances.This
canbeunfortunate,sinceitmaycauseexcessivevibration,premature
wear,andearlyfailure.Thisgetsusbacktotheneedforhavingthe
toolsandknowledgefordoingagoodalignmentjobefficiently.So
muchforthepropagandanowforthetolerances.
Tolerancesmustbeestablishedbeforealignment,inordertoknow
whentostop.Varioustolerancebasesexist.Oneauthority
recommendshmilmaximumcenterlineoffsetperin.ofcoupling
length,forhotrunningmisalignment.Anumberofmanufacturershave
graphswhichrecommendtolerancesbasedoncouplingspanand
speed.Acommontoleranceintermsoffaceandrimmeasurementsis
.003in.allowablefacegapdifferenceandcenterlineoffset.This
ignorestheresultingaccuracyvariationduetofacediameterand
spacerlengthdifferences,butworksadequatelyformanymachines.
Becautiousinusingalignmenttolerancesgivenbycoupling
manufacturers.Thesearesometimesratherliberaland,whileperhaps
trueforthecouplingitself,maybeexcessiveforthecoupled
machinery.AbetterguidelineisillustratedinFigure52,whichshows
anupper,absolutemisalignmentlimit,andalower,dontexceedfor
goodlongtermoperationlimit.Therealcriterionistherunning
vibration.Ifexcessive,particularlyattwicerunningfrequencyand
axially,furtheralignmentimprovementisprobablyrequired.Analysis
offailedcomponentssuchasbearings,couplings,andsealscanalso
indicatetheneedforimprovedalignment.
Figure52canbeappliedtodetermineallowablemisalignmentfor
machineryequippedwithnonlubricatedmetaldiscanddiaphragm
couplings,uptoperhaps10,000rpm.Ifthemachineryisfurnishedwith
geartypecouplings,Figure52shouldbeusedupto3,600rpmonly.At
speedshigherthan3,600rpm,gearcouplingswilltoleratewithimpunity
onlythoseshaftmisalignmentswhichlimittheslidingvelocityof
engaginggearteethtolessthanperhaps120in.perminute.Forgear
couplings,thisvelocitycanbeapproximatedbyV=(TDN)tancr,where
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resimmmmmmSay,forexample,weweredealingwitha3560rpm
pumpcoupledtoamotordrivenviaa6in.pitchdiametergear
coupling.Weobserveatotalindicatorreadingof26milsinthevertical
planeandatotalindicatorreadingof12milsinthehorizontalplane.
Thedistancebetweentheflexingmemberofthecoupling,i.e.,flexing
memberondriverandflexingmemberondrivenmachine,is10in.
Thetotalnetindicatorreadingis[(26)2+(12)?]''*=28.6mils.TanCY
=(1/2)(28.6)/10)=1.43milslin.,or0.00143in./in.Theslidingvelocity
istherefore[(~)(6)(3560)(0.00143)1=96in.perminute.Sincethisis
belowthemaximumallowableslidingvelocityof120in.perminute,
theinstallationwouldbewithinallowablemisalignment.
ChoosinganAlignmentMeasurementSetup
Havingtakencareofthepreliminaries,wearenowreadytochoose
analignmentsetup,orarrangementofmeasuringinstruments.Many
suchsetupsarepossible,generallyfallingintothreebroadcategories:
faceandrim,reverseindicator,andfacefacedistance.Thefollowing
sketchesshowseveralofthemorecommonsetups,numbered
arbitrarilyforeaseoffuturereference.Notethatifmeasurementsare
takenwithcalipersorIDmicrometers,itmaybenecessarytoreverse
thesignfromthatwhichwouldapplyifdialindicatorsareused.
Figures53through58showseveralcommonarrangementsof
indicators,jigs,etc.Otherarrangementsarealsopossible.For
example,Figures53and54canbedonewithjigs,eitherwithor
withoutbreakingthecoupling.Theycanalsosometimesbedone
whennospacerispresent,byusingrightangleindicatorextension
tips.Figures56and57canbesetupwithbothextensionarmsand
indicatorsonthesameside,
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ratherthan180"oppositeasshown.Insuchcases,however,asign
reversalwilloccurinthecalculations.Also,wecanindicateonbackof
face,asforconnectedmetaldisccouplings.Again,asignreversalwill
occur.Inchoosingthesetuptouse,personalpreferenceandcustom
willnaturallyinfluencethedecision,butherearesomebasic
guidelinestofollow.
ReverseIndicatorMethod
Thisisthesetupwepreferformostalignmentwork.Asillustratedin
Figure59,ithasseveraladvantages:
1.Accuracyisnotaffectedbyaxialmovementofshaftsinsleeve
bearings.
2.Bothshaftsturntogether,eithercoupledorwithmatchmarks,so
couplingeccentricityandsurfaceirregularitiesdonotreduceaccuracy
ofalignmentreadings.
3.Facealignment,ifdesired,canbederivedquiteeasilywithoutdirect
measurement.
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4.Rimmeasurementsareeasytocalibrateforbracketsag.Facesag,by
contrast,isconsiderablymorecomplextomeasure.
5.Geometricaccuracyisusuallybetterwithreverseindicatormethodin
processplants,wheremostcouplingshavespacers.
6.Withsuitableclamponjigs,thereverseindicatormethodcanbeused
quiteeasilyformeasuringwithoutdisconnectingthecouplingor
removingitsspacer.Thissavestime,andforgearcouplings,reducesthe
chanceforlubricantcontamination.
7.Forthemorecomplexalignmentsituations,wherethermalgrowth
and/ormultielementtrainsareinvolved,reverseindicatorcanbeused
quitereadilytodrawgraphicalplotsshowingalignmentconditionsand
moves.Itisalsousefulforcalculatingoptimummovesoftwoormore
machineelements,whenphysicallimitsdonotallowfullcorrectiontobe
madebymovingasingleelement.
8.Whenusedwithjigsandposts,singleaxislevelingissufficientforball
bearingmachines,andtwoaxislevelingwillsufficeforsleevebearing
machines.
9.Forlongspans,adjustableclamponjigsareavailablefor
reverseindicatorapplication,withoutrequiringcouplingspacerremoval.
Faceandrimjigsforlongspans,bycontrast,areusuallynonadjustable
custombracketsrequiringspacerremovaltopermitfacemounting.
10.Withthereverseindicatorsetup,wemountonlyoneindicatorper
bracket,thusreducingsagascomparedtofaceandrim,whichmounts
twoindicatorsperbracket.(Faceandrimcandoitwithoneperbracketif
weusetwobrackets,orifweremountindicatorsandrotateasecond
time,butthisismoretrouble.)
Therearesomelimitationsofthereverseindicatormethod.Itshouldnot
beusedonclosecoupledinstallations,unlessjigscanbeattached
behindthecouplingstoextendthespanto3in.ormore.Failureto
observethislimitationwillusuallyresultincalculatedmoveswhich
overcorrectforthemisalignment.
Bothcoupledshaftsmustberotatable,preferablybyhand,and
preferablywhilecoupledtogether.Ifonlyoneshaftcanberotated,orif
neithercanberotated,thereverseindicatormethodcannotbeused.If
thecouplingdiameterexceedsavailableaxialmeasurementspan,
geometricaccuracywillbepoorerwithreverseindicatorthanwith
faceandrim.
Ifrequiredspanexceedsjigspancapability,eithergetabiggerjigor
changetoadifferentmeasurementsetupsuchasfacefacedistance.
Coolingtowerdriveswouldbeanexampleofthis.
FaceandRimMethod
Thisisthetraditionalsetupwhichisprobablythemostpopular,al
Advantagesoffaceandrim:
1.Itcanbeusedonlarge,heavymachineswhoseshaftscannotbe
2.Ithasbettergeometricaccuracythanreverseindicator,forlargedi
3.Itiseasiertoapplyonshortspanandsmallmachinesthanisrethough
itislosingfavorasmorepeoplelearnaboutreverseindicator.turned.
ametercouplingswithshortspans.
verseindicator,andwilloftengivebetteraccuracy.Limitationsofface
andrim:1.Ifusedonamachineinwhichoneorbothshaftscannotbe
turned,somerunouterrormayoccur,duetoshaftorcoupling
eccentricity.
Ifusedonasleevebearingmachine,axialfloaterrormayoccur.One
methodofavoidingthisistobumptheturnedshaftagainsttheaxialstop
eachtimebeforereading.Anotherwayistouseasecondfaceindicator
180"aroundfromthefirst,andtakehalfthealgebraicdifferenceofthe
twofacereadingsafter180"rotationfromzerostart.Figure510
illustratesthisalignmentmethod.Two2411.tubulargraphitejigsare
usedforlightweightandhighrigidity.Ifusedwithjigsandposts,twoor
threeaxislevelingisrequired,forballandsleevebearingmachines
respectively.Reverseindicatorrequireslevelinginonelessaxisfor
each.
Faceandrimhaslowergeometricaccuracythanreverseindicator,for
spansexceedingcouplingorjigdiameter.
Facesagisofteninsignificant,butitcanoccuronsomesetups,and
resultinerrorsifnotaccountedfor.Calibrationforfacesagis
considerablymorecomplexthanforrimsag.
Forlongspans,faceandrimjigsareusuallycustombuiltbrackets
requiringspacerremovaltopermitfacemounting.Longspanreverse
indicatorjigs,bycontrast,areavailableinadjustableclamponmodelsnot
requiringspacerremoval.
Graphingtheresultsoffaceandrimmeasurementsismorecomplex
thanwithreverseindicatormeasurements.
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FaceFaceDistanceMethod
Advantagesoffacefacedistance:
1.Itisusableonlongspans,suchascoolingtowerdrives,without
elaboratelongspanbracketsorconsiderationofbracketsag.
2.ItisthebasisforthermalgrowthmeasurementintheIndikonproximity
probesystem,andagainisunaffectedbylongaxialspans.
3.Itissometimesaconvenientmethodforusewithdiaphragmcouplings
suchasBendixandKoppers,allowingmountingofindicatorholderson
spacertube,withindicatorcontactpointsondiaphragmcovers.
Limitationsoffacefacedistance:
1.Ithasnoadvantageovertheothermethodsforanythingexceptlong
spans.
2.Itcannotbeusedforinstallationswherenocouplingspacerispresent.
3.Itsgeometricaccuracywillnormallybelowerthaneitheroftheother
twomethods.
4.Itmayormaynotbeaffectedbyaxialshaftmovementinsleeve
bearings,butthiscanbeavoidedbythesametechniquesasforface
andrim.
LaserOpticAllgnment
Intheearly1980s,bymeansofearthboundlaserbeamsandareflector
mountedonthemoon,manhasdeterminedthedistancebetweenearth
andthemoontowithinabout6inches.Suchaccuracyisafeatureof
opticalmeasurementsystems,aslighttravelsthroughspaceinstraight
lines,andabundledlaserraywithparticularprecision.
Thus,criticalmachineryalignment,whereaccuracyofmeasurementisof
paramountimportance,isanidealapplicationforalaseropticalignment
system.
Theinherentproblemsofmechanicalprocedureandsequenceof
measuringhavebeensolvedbyPrueftechnikDieterBusch,of8045
Ismaning(WestGermany),whoseOPTALIGN@systemcomprisesa
semiconductorlaseremittingabeamintheinfraredrange(wavelength
820mm),alongwithabeamfinderincorporatinganinfrareddetector.The
laserbeamisrefractedthroughaprismandiscaughtbya
receiver/detector.
Theselightweight,nonbulkydevicesaremountedontheequipmcnt
shafts,andonlyacordconnectedmicrocomputermoduleisexternalto
thebeamemissionandreceiverldetectordevices.Theprismredirects
thebeamandallowsmeasurementofparalleloffsetinoneplaneand
angularityinanother,thussimultaneouslycontrollingboth.Inone360"
rotationoftheshaftsallfourdirectionalalignmentcorrectionsare
determined.
Thereceiverisabiaxialanalogphotoelectricsemiconductorposition
detector,yieldingmathematicalresultstowithinonemicron.Datafor
computationareenteredautomaticallythroughacabledirectfromthe
receiver/detector.Theonlyinformationstilltobeenteredmanuallyisthe
relativeposition,4times,at0,90,180and270".
Withthedataautomaticallyobtainedfromthereceiver/detector,the
microcomputerinstantaneouslyyieldsthehorizontalandvertical
adjustmentresultsforthealignmentofthemachinetobemoved.
Physicalcontactbetweenmeasuringpointsonbothshaftsisnolonger
required,asthisisnowbridgedbythelaserbeam,eliminatingthe
possibilitiesforerrorarisingfromgravitationalhardwaresagaswellas
fromstickydialindicators,etc.Thesystem'sbasicattachmentisstill
carriedoutwithastandardquickfitbracketingsystem,orwithanyother
suitableattachmenthardware.
IfthereaderownsanOPTALIGN@system,hedoesnothavetobe
concernedwithsag.Otherreadersmustcontinuethecheckoutprocess.
CheckingforBracketSag
Longspansbetweencouplinghalvesmaycausethedialindicatorfixture
tosagmeasurablybecauseoftheweightofthefixtureandthedial
indicators.Althoughsagmaybeminimizedbyproperbracing,sag
effectsshouldstillbeconsideredinverticalalignment,Todeterminesag,
installthedialindicatorsonthealignmentfixtureinthesameorientation
andrelativepositionasintheactualalignmentprocedurewiththefixture
restingonalevelsurfaceasshowninFigure51I.Withasmallslingand
scale,lifttheindicatorendofthefixturesothatthefixtureisinthe
horizontalposition.Notethereadingonthescale.Assumeforexample
thatthescalereadingwas7.5Ibs.Next,mountthealignmentfixtureon
thecouplinghubwiththedialindicatorplungertouchingthetopvertical
rimoftheoppositecouplinghub.Setthedialindicatortozero.Next,
locatetheslinginthesamerelativepositionasbeforeand,while
observingthescale,applyanupwardforcesoastorepeattheprevious
scalereading(assumed7.5Ibsinourexample).Notethedialindicator
readingwhileholdingtheupwardforce.
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Letusassumeforexamplethatweobserveadialindicatorreadingof
0.004in.Usingthisspecificmethodology,sagerrorappliesequally
tothetopandbottomreadings.Therefore,thesagcorrectiontothe
totalindicatorreadingisdoubletheindicatedsagandmustbe
algebraicallysubtractedfromthebottomverticalparallelreading,i.e.,
(2)(.004)=+.008correctiontobottomreading.Thismethodisa
cleveroneforfacemountedbrackets.Forclamponbrackets,
however,itwouldbeeasierandmorecommontoattachthemtoa
horizontalpipeonsawhorses,androlltoptobottom.Figure512
showsthisconventionalmethodwhich,exceptforthesag
compensatordevice,isalmostuniversallyemployed.Thesag
compensatorfeatureincorporatesaweightbeamscalewhichapplies
anupwardforcewhentheindicatorbracketislocatedatthetopofthe
machineshaft,andanequal,butopposite,forcewhentheindicator
bracketandshaftcombinationisrotatedtothedownposition,180"
removed.
Inanyevent,letusassumethatweobtainreadingsof0and+0.160
in.atthetopandbottomverticalparallelsrespectively.Wecorrectfor
saginthefollowingmanner:
BracketSagEffectonFaceMeasurements
Bracketsagisgenerallythoughttoprimarilyaffectrimreadings,with
littleeffectonfacereadings.Oftenthisistrue,butsomeriskmaybe
incurredbyassumingthiswithoutatest.Unlikerimsag,facesag
effectdependsnotonlyonjigorbracketstiffness,butonitsgeometry.
Determiningfacesageffectisfairlyeasy.Firstgetrimsagforspanto
beused(wearereferringheretothefullindicatordeflectiondueto
sagwhenthesetupisrotatedfromtoptobottom).Thismaybe
obtainedbytrial,withrimindicatoronly,orfromagraphofsags
compiledforthebrackettobeused.Theninstallasetupwithrim
indicatoronly,onCalibrationpipeoronactualfieldmachine,andlay
onthefaceindicatorandaccessories,notingadditionalrimindicator
deflectionwhenthisisdone.Doublethisadditionaldeflection,andadd
ittotherimsagfoundpreviously,ifboththefaceandrimindicators
aretobeusedsimultaneously.Ifthefaceandtherimindicatorsareto
beusedseparately,toreducesag,usetheoriginalrimsaginthe
normalmanner,andusethissameoriginalrimsagasshortlytobe
describedindeterminingfacesageffectinthislattercaseutilizinga
rimindicatorinstalledtemporarilywiththefaceindicatorforthis
purpose.Ifthefaceindicatorisadifferenttype(Le.,differentweight)
fromtherimindicator,obtainrimsagusingthisfaceindicatoronthe
rim,andusethisfiguretodeterminefacesageffect.
Nowinstallfaceandrimsetupontheactualmachine,andzerothe
indicators.Withindicatorsatthetop,deflectbracketupwardan
amountequaltotheappropriaterimsag,readingontherimindicator,
andnotethefaceindicatorreading.Thefacesagcorrectionwith
indicatorsatbottomwouldbethisamountwithoppositesign.If
zeroingthesetupatthebottom,thefacesagcorrectionatthetop
wouldbethisamountwithsamesign(iforiginallydeterminedattop,
asdescribed).
FaceSagEffectExamples
Example1
FaceandrimindicatorsaretobeusedtogetherasshowninFigure5
3.Assumeyouwillobtainthefollowingfromyoursagtest:Rimsag
withrimindicatoronly=.004in.Rimsagwithtwoindicators=.007in.
Mountthesetuponthemachineinthefield,andwithindicatorsattop,
deflectthebracketupward.007in.asmeasuredontherimindicator.
Whenthisisdone,thefaceindicatorreadsplus.002in.Facesag
correctionatthebottompositionwouldthereforebeminus.002in.If
youwishtozeroatthebottomforalignment,butotherwisehavedata
asnoted,thefacesagcorrectionatthetopwouldbeplus.002in.
Example2
Faceandrimindicatorsaretobeusedseparatelytoreducesag.Both
indicatorsarethesametypeandweight.Otherbasicdataarealsothe
same.
Installfaceindicatorandtemporaryrimindicatoronthemachineinthe
field,andplaceintopposition.Zeroindicatorsanddeflectupward
,004in.asmeasuredonrimindicator.Faceindicatorreadsplus.0013
in.Facesagcorrectionatthebottomwouldthereforebeminus.0013
in,Ifzeroingatthebottomforalignment,butotherwisethesameas
above,facesagcorrectionattopwouldbeplus.0013in.Example3
Thiswilldeterminesagfor3IndicatorFaceandRimSetupshownin
Figure54.
Setupthejigtothesamegeometryasforfieldinstallationbutwithrim
indicatoronlyandroll180toptobottomonpipetogettotalsingle
indicatorrimsag(Step1).
Zerorimindicatorontopandaddorlayonfaceindicator,notingrim
indicatordeflectionthatoccurs(Step2).Doublethis__(Step3).
Addittooriginaltotalsingleindicatorrimsag(Step1).(Step4).This
figure,precededbyaplussign,willbethesagcorrectionfortherim
indicatorreadingstakenatbottom.Withfieldmeasurementsetupas
shown,zeroallindicators,anddeflecttheindicatorendoftheupper
bracketupwardanamountequaltothetotalrimsag(Step4).Note
thefacesageffectbyreadingthefaceindicator.Thisamount,with
oppositesign,isthefacesagcorrectiontoapplytothereadingstaken
atthelowerposition(Step5).Nowdeflecttheupperbracketback
downfromitstotalrimsagdeflectionanamountequaltoStep3.
Theamountofsagremainingonthefaceindicator,precededbythe
samesign,isthesagcorrectionforthesinglefaceindicatorbeing
readatthetopposition(Step6).
Alloftheforegoingrefersofcoursetobracketsag.Inlongmachines,
wewillalsohaveshaftsag.Thisismentionedonlyinpassing,since
thereisnoneedtodoanythingaboutitatthistime.Ourpointby
pointalignmentwillautomaticallytakecareofshaftsag.Forinitial
levelingoflargeturbogenerators,etc.,especiallyifusingprecision
opticalequipment,shaftsagmustbeconsidered.Manufacturersof
suchmachinesknowthis,andprovidetheirerectorswithsuitabledata
forsagcompensation.Furtherdiscussionofshaftsagisbeyondthe
scopeofthistext.
LevelingCurvedSurfaces
Itiscommonpracticetosetuptherimdialindicatorssotheir
contacttipsrestdirectlyonthesurfaceofcouplingrimsorshafts.If
grossmisalignmentisnotpresent,andifcouplingand/orshaft
diametersarelarge,whichisusuallythecase,accuracywilloften
beadequate.If,however,majormisalignmentexists,and/ortherim
orshaftdiametersaresmall,asignificanterrorislikelytobe
present.Itoccursduetothemeasurementsurfacecurvature,as
illustratedinFigures513and514.Thiserrorcanusuallybe
recognizedbyrepeatedfailureoftopplusbottom(T+B)readings
toequalsideplusside(S+S)readingswithinoneortwo
thousandthsofaninch,andbycalculatedcorrectionsresultingin
animprovementwhichundershootsorovershootsandrequires
repeatedcorrectionstoachievedesiredtolerance.Awayto
minimizethiserroristousejigs,posts,andaccessorieswhich
squarethecircle.Hereweattachflatsurfacesorpoststothe
curvedsurfaces,andlevel
themattopandbottomdeadcenter.Thiscorrectstheerrorasshown
inFigure514.
Forthismethodtobefullyeffective,rotationshouldbeperformedat
accurate90quadrants,usinginclinometerorbubblevialdevice.In
mostcases,however,thiserrorisnotenoughtobothereliminatingit
iseasierjusttomakeafewmorecorrectivemoves,reducingtheerror
eachtime.
JigPosts
Theprecedingexplanationshowedarudimentaryauxiliarysurface,or
jigpost,usedforsquaringthecircle.Amorecommonreasonfor
usingjigpostsistopermitmeasurementwithoutremovingthespacer
onaconcealedhubgearcoupling.Ifjigpostsareused,itisimportant
thattheybeusedproperly.Ineffect,wemustensurethatthesurfaces
contactedbytheindicatorsmeetthesecriteria:
Asalreadyshown,theymustbeleveledincoordinationattopand
bottomdeadcenters,toavoidinclinedplaneerror.
Ifanyaxialshaftmovementcanoccur,aswithsleevebearings,the
surfacesshouldalsobemadeparalleltotheirshafts.Thiscanbe
donebylevelingaxiallyatthetop,rotatingtothebottom,and
rechecking.Ifbubbleisnotstilllevel,tiltthesurfacebacktowardlevel
forahalfcorrection.
Iffacereadingsaretobetakenonposts,thepostfacesurfaces
shouldbemachinedperpendiculartotheirrimsurfaces.Inadditionto
this,andtosteps1and2justdescribed,rotateshaftssopostsare
horizontal.Usingalevel,adjustfacesurfacessotheyarevertical.
Rotate180andrecheckwithlevel.Ifnotstillvertical,tiltbacktoward
verticaltomakeahalfcorrectiononthebubble.Thiswillaccomplish
ourdesiredobjectiveofgettingthefacesurfaceperpendiculartothe
shaftinallmeasurementplanes.
Theforegoingassumesuseoftriaxiallyadjustablejigposts.Ifsuch
postsarenotavailable,itmaybepossibletogetgoodresultsusing
accuratelymachinednonadjustableposts.Ifreadingsandcorrections
donotturnoutasdesired,however,itcouldpaytomakethelevel
checksasdescribedtheymightpinpointtheproblemandsuggesta
solutionsuchasusinganonpostmeasurementsetup.
interpretationandDataRecording
Duetosagaswellasgeometryofthemachineinstallation,itis
difficultanddeceptivetotrysecondguessingtheadequacyof
alignmentsolelyfromtherawindicatorreadings.Itisnecessaryto
correctforsag,thennotetheinterpretedreadings,thenplotor
calculatethesetoseetheoverallpictureincludingequivalentface
misalignmentifprimaryreadingswerereverseindicatoronrimsonly.
Sometimesthermaloffsetsmustbeincluded,whichfurther
complicatestheoverallpicture.Asawaytosystematicallyconsider
thesefactorsandarriveatasolution,itishelpfultouseprepareddata
formsandstepwisecalculation.Supposeweareusingthetwo
indicatorfacerimmethodshowninFigure53letscallitSetup#1.
Tostart,prepareadatasheetasshowninFigure515.Next,measure
andfillinthebasicdimensionsatthetop.Then,fillintheorientation
direction,whichisnorthinourexample.Next,takeaseriesof
readings,zeroingatthetop,andreturningforfinalreadingswhich
shouldalsobezeroornearlyso.Nowdoafurthercheck:Addthetop
andbottomreadingsalgebraically(T+B),andaddthesidereadings
(S+S).Thetwosumsshouldbeequal,ornearlyso.Ifthechecksare
poor,takcanewsetofreadings.Dothechecksbeforeaccountingfor
bracketsag.Now,fillintheknownorassumedbracketsag.Ifthe
bracketdoesnotsag(optimist!),fillinzero.Combinethesag
algebraicallywiththeverticalrimreadingasshown,andgetthenet
readingusing(+)or()asappropriatetoaccomplishthesag
correction.Awellpreparedformwillhavethissignprintedonit.Ifit
doesnot,mentallyfigureoutwhatmustbedonetounsagthe
bracketinthefinalposition,andwhatsignwouldapplywhendoingso.
Nowwearereadytointerpretourdatainthespaceprovidedonthe
form.Todothis,firsttakehalfofournetrimreading:
Formullll
Thisisbecausewearelookingforcenterlineratherthanrimoffset.
Sinceitssignisminus,wecanseefromtheindicatorarrangement
sketchthatthemachineelementtobeadjustedishigherthanthe
stationaryelement,attheplaneofmeasurement.Thisassumesthe
useofaconventionalAmericandialindicator,inwhichapositive
readingindicatescontactpointmovementintotheindicator.
Bythesamereasoning,wecanseethatthebottomfacedistance
is.007in.widerthanthetopfacedistance.Goingnowtothe
horizontalreadings,wemakethenorthrimreadingzerobyadding
.007in.toit.Topreservetheequalityofouralgebra,
wealsoadd.007in.tothesouthrimreading,givingus.029in.
Takinghalfofthis,wefindthatthemachineelementtobeadjusted
is.0145in.northofthestationaryelementattheplaneof
measurement.Finally,wedoasimilaroperationonourhorizontal
facereadings,anddeterminethatthenorthfacedistanceiswider
by.014in.Theremainingpartoftheformprovidesspacetoputthe
calculatedcorrective
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Nelsonsmethodiseasytounderstand,anditworks.Itisbasically
afourstepprocedureinthisorder:
1.VerticalangularCorrection.
2.Verticalparallelcorrection.
3.Horizontalangularcorrection.
4.Horizontalparallelcorrection.
Ithasthreedisadvantages,however.
First,itrequiresfoursteps,whereasthemorecomplex
mathematicalmethodscancombineangularandparalleldata,
resultinginatwostepcorrection.Secondly,itisquitelikelythat
initialangularcorrectionwillsubsequentlyhavetobepartiallyun
done,whenmakingthecorrespondingparallelcorrection.Nobody
likestocutandinstallshims,thenendupremovinghalfofthem.
Finally,itisdesignedonlyforfaceandrimsetups,anddoesnot
applytotheincreasinglypopularreverseindicatortechnique.
Wewillnowshowtwoadditionalexamples,whereintheangular
andparallelcorrectionarecalculatedatthesametime,foran
overalltwostepcorrection.Frankly,weourselvesnolongeruse
thesemethods,nordowestilluseNelsonsmethod,butare
includingthemhereforthesakeofcompleteness.Graphical
methods,asshownlater,areeasierandfaster.Inparticular,the
alignmentplottingboardshouldbejudgedextremelyuseful.
Readerswhoarenotinterestedinthemathematicalmethodmay
wishtoskiptopage192,wherethemucheasiergraphicalmethods
areexplained.But,inanyevent,hereisthefullmathematical
treatment.
Inourfirstexample,wewillreusethedataalreadygiveninour
setupNo.1datasheet.
First,wewillsolveforverticalcorrections:
UsingNelsonsmethod,wefounditnecessarytomakea0.053in.
shimcorrection.Letusarbitrarilysaythiswillbeashimaddition
beneaththeinboardfeet.Atthecouplingface,wethengetarise
of:
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Asyoucansee,thevaluesfoundthiswayareclosetothosefound
earlier.Themainproblempeoplehavewithapplyingthese
formulasischoosingbetweenplusandminusfortheterms.The
easiestway,inouropinion,istovisualizetheasfoundconditions,
andthiswillpointthewaythatmovementmustproceedtogoto
zeromisalignment.Forexample,ourbottomfacedistanceiswide
thereforeweneedtolowerthefeet(pivotingatplaneA)whichwe
denotewithaminussign.Themachineelementtobeadjustedis
higheratplaneAsoweneedtoloweritsomemore,whichtakes
anotherminussign.Forthehorizontal,ournorthfacedistanceis
wider,soweneedtomovethefeetnorth(againpivotingatplane
A).ThemachineelementtobeadjustedisnorthatplaneA,sowe
needtomoveitsouth.Callnorthplusorminus,solongasyoucall
souththeoppositesign.Notreallyhard,butalotofpeoplehave
troublewiththeconcept,whichiswhyweprefertoconcentrateon
graphicalmethods,wheredirectionofmovementbecomesmore
obvious.Wewillgetintothisshortly,butfirstletsdoareverse
indicatorproblemmathematically.
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Forourreverseindicatorexample,wewillusethesetupshown
earlierasFigure56.Also,wemustnowrefertotheappropriate
datasheet,Figure518.Finally,weresorttosometriangles,
Figures519and520,toassistusinvisualizingthesituation.
TeknikResimmm
GraphicalTechniques
Nowletsseehowwecandothesamethingmoreeasily.Todo
this,wewillturntographicaltechniques.Reference7showsone
versionofthisinanarticleonalignmentofbarreltypecentrifugal
compressors.Itsauthorstretchesastripchartoutonadrafting
table,andrulesinthemachineelementshafts,toscale,orientedas
shownbyreverseindicatorreadings,muchaswedidinour
previousexample.Movementstoachievezerooffset,orto
compensateforthermalgrowth,canthenbeplottedonthesame
sheet.Thistechniquehastheadvantageofgivingacompleteand
permanentwrittenvisualrecordofwhatishappening,andis
especiallyusefulonmultielementmachinery
Afterreworkingourfirstexamplewiththealignmentplottingboard,
wewillproceedtooursecondexample,usingthereverseindicator
setup(setup4).ThisisillustratedforusinFigures518and524.
Wewillthengoonandgiveworkedoutexamplesusingtheother
setupsinFigures525through533.
ThreeIndicatorFaceandRim
Figure527depictsapumpwithballbearingsdrivenbyamotor
havingsleevebearings.Externalobstructionspreventtheuseof
setups4or5,andthecouplingsurfaceshaveconsiderablerunout,
makingsetup1inadvisable.Itisthereforedecidedtousesetup2
thethreeindicatorfaceandrim.Asagcheckshows0.002in.sag
fortherimindicatorbracket.Sagforthefaceindicatorswillbe
ignored.Apreliminarystraightedgealignmentismadeinthe
horizontalplane.Bothshaftsarethenturnedtogetherandasetof
verticalreadingstakenasshownontheaccompanyingdatasheet
inFigure528.
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trainssuchasthearticlediscusses.
Anothergraphicaltechnique,whichwepreferformostsituations,is
theAlignmentPlottingBoard.Itisfast,easy,andaccurate,particularly
onthesimpletwoelementtrainscomprisingthemajorityofall
machines.Itcanbeusedonmultielementtrains,butislessefficient
thangraphpaperbeyondtwoelements.Toourknowledge,theplotting
boardistheonlymethodwhichhandlesboththefaceandrimand
reverseindicatorsetupswithequaleaseandcanconvertfromRIto
F&R.Anadditionaladvantageisitsportabilityitisonly8V2X11in.
andismadefromanindestructiblepolycarbonateplastic.Figure5
22showsitinuse.
Letsreturntoourfirstexample.Forconvenience,wewillrefertothe
datasheetinFigure515,thenshowhowtofindthecorrectionson
theplottingboard.ThisisgraphicallyexplainedinFigure523.By
flippingbackandforthbetweendatasheetandplottingboard
sketches,youcanseewheretheanswerscomefrom.Itwillhelpto
alsoreadtheinstructionsthatcomewiththeplottingboard,ifyou
haveone.Withpractice,theanswerswillappearinaminuteortwo.
movements.Althoughthesehavebeenfilledinforourexample,lets
leavethemforthetimebeing,sincewearenotyetreadytoexplain
thecalculationprocedure.Wewillshowyouhowtogetthesenumbers
later.Ifyouthinkyoualreadyknowhow,goaheadandtrytheresults
maybeinteresting.
Youhavenowseenthegeneralideaaboutdatarecordingand
interpretation.Bydoingitsystematically,onapreparedform
correspondingtotheactualfieldsetup,youcanminimizeerrors.Ifyou
areinterrupted,youwillnothavetowonderwhatthosenumbers
meantthatyouwrotedownonthebackofanenvelopeanhourago.
Wewilldeferconsiderationoftheremainingsetups,untilwehave
explainedhowtocalculatealignmentcorrectivemovements.Wewill
thentakenumericalexamplesforallthesetupsillustrated,andgo
throughthemalltheway.CalculatingtheCorrectiveMovements
Manymachinistsmakealignmentcorrectivemovementsbytrialand
error.Aconscientiouspersoncaneasilyspendtwodaysaligninga
machinethisway,butbyknowinghowtocalculatethecorrections,the
timecanbecuttotwohoursorless.
Severalmethods,bothmanualandelectronic,existfordoingsuch
calculations.All,ofcourse,arebasedongeometry,andsomeare
rathercomplicatedanddifficulttofollow.Forthoseinterestedinsuch
things,seeRefercnces1through15.Also,thealignmentspecialist
shouldbeawareofprogrammablecalculatorsolutions.Thesemake
useofpopularcalculatorssuchastheTI59andHP67.Byrecording
thealignmentmeasurementsonapreparedform,andenteringthese
figuresintheprescribedmannerintothecalculator,therequired
movescomeoutasanswers.AvariationofthisistheTRS80pocket
computerwhichhasbeenprogrammedtodoalignmentcalculations
viasuccessiveinstructionstotheusertellinghimwhatinformationto
enter.
Byfarthesimplestcalculatoristheonedescribedearlierin
conjunctionwiththelaserbasedOPTALIGN@system.Nexttoit,we
ranktheIMScalculator.l4Thisisdesignedspecificallyfromthe
groundupforthemorecommonfaceandrimandreverseindicator
calculations,ratherthanbeingastandardcommercialcalculatoror
computeradaptedforalignment.Forthemorecomplexmultielement
trains,largercentralcomputerscanbeuseddirectlywithtelephone
linkups.RayDoddsbook(TotalAlignment,Reference3)describes
onesuchsystem.Anotherthatwesawdemonstratedprovidesnot
onlythenumericaldata,butadiagrammaticrepresentationofthe
machinesandtheiralignmentrelationship,onacathoderaytube.
Theforegoingelectronicsystemsarepopular,andhaveadvantagesin
speed,accuracy,andeaseofuse.Theyhavedisadvantagesincost,
usabilityunderadversefieldandhazardousareaconditions,pilferage,
sensitivitytodamagefromtemperatureextremesandroughhandling,
andavailabilitytothefieldmachinistat2:OOA.M.onaholiday
weekend.Theyalso,forthemostpart,workmainlywithnumbers,and
theanswersmayrequireacceptanceonblindfaith.Bycontrast,
graphicalmethodsinherentlyaidvisualizationbyshowingthe
relationshipofadjacentshaftcenterlinestoscale.
Manualcalculationmethodshavetheadvantageoflowinvestment
(pencilandpaperwillsuffice,butaslideruleorsimplecalculatorwill
befaster).Theyhavethedisadvantage,somesay,ofrequiringmore
thinkingthantheprogrammedelectronicsolutions,particularlyto
choosetheplusandminussignscorrectly.
Thegraphicalmethods,whichweprefer,havetheadvantageofaiding
visualizationandavoidingconfusion.Theiraccuracywillsometimes
belcssthanthatofthepuremathematicalmethods,butusuallynot
enoughtomatter.Investmentislowgraphpaperandplottingboards
areinexpensive.Speedishighonceproficiencyisattained,which
usuallydoesnottakelong.
Inthistext,wewillemphasizethegraphicalapproach.Beforedoing
so,letshighlightsomecommonmanualmathematicalcalculations.
Nelsonpublishedanexplanationofonerathersimplemethoda
numberofyearsago.AshortenedexplanationisgiveninFigure516.
Forourgivenexample,thiswouldworkoutasfollows:
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Posted10thSeptember2008byAmrZoair
300offonFlights
DelhitoGoaUsecode:DOM300
5 Viewcomments
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