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AlignmentandBalancing

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.

Piping Is connecting piping well fitted and supported, and sufficiently


flexible, so that no more than 0.003 in. vertical and horizontal
(measured separately not total) movement occurs at the flexible
coupling when the last pipe flanges are tightened? Selective flange
bolt tightening may be required, while watching indicators at the
coupling. If pipe flange angular misalignment exists, a dutchman or
tapered filler piece may be necessary. To determine filler piece
dimensions,

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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XY8/SMm5AJSJFI/AAAAAAAAAUw/HgRLdYPP8UE/s1600h/24.bmp]

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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Reply

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