Alignment Training

1. Safety precautions during alignment jobs

2. Units of measurements. ( to check the knowledge of measurement )
3. Measuring instruments - related to alignment.( brief explanation of
vernier caliper, micrometer, feeler gauge and
dial indicators )
4. What is rotating equipment and its construction( introduction of
bearings, mechanical seal, oil seals internal clearance, etc)
5. What is prime mover and types (electrical motors, turbine, diesel
engine)
6. Shaft couplings (brief explanation of types, and installation method,
relation with alignment)
7. Rotating equipment installation (brief explanation about installation,
leveling, piping etc.)
8. Why we need alignment and type of alignment
9. Preparing for alignment getting equipment data (rpm, coupling hub
dia, DBSC, driver leg distances),
Arranging bracket, dial indicators
or optical inst, isolation of power, etc..
10. Pre alignment (coupling gap adjustment, soft foot checking and rough
alignment).
11.Alignment by Rim @ face method
12.By Reverse indicator method, formula and graphical sheet method
13.Laser alignment
14. Hot alignment or offset alignment
15. Tolerance for alignment.
16. Keeping record.
17. Alignment manager ( software ) for Rim @ Face and Reverse method of
alignment ( hand out )
18. Practical training
19. Hand out of Calculation and Graphic sheets
20. Test (written/ Practical)
21. Training Record send to training Department.

Safety precautions to be followed during alignment.

1. Isolate the power sources and follow the lock out tag out procedure of the
equipment to avoid accidently machine starts by someone
2. Isolate the process pipe lines by closing the inlet and out let valves. May be
back flow of the handling fluids will rotate the shaft and cause accident.
3. Use proper tools to avoid hand injury and damage machinery.
4. Use proper hand gloves during handling of sharp edged metal shims.
5. Properly plan to lift the motor either by jack screws on the base or by
hydraulic jacks according to the size and weight.
6. Avoid to put fingers under the base for cleaning and placing the metal shims,
if jack slip your finger may caught between the bases and may cut it.
7. Use proper tools to install the coupling spacer, and care about fingers, it may
caught between the spacer and coupling hub.
8. Dispose the waste and scrap metal shims properly.

9. Avoid to cross the laser beam by bodily between the transducer and reflector
even thogh it is designed for safe human use.
10.
Use only calibrated measuring instruments.
11.
Properly store the measuring instruments in its case.

Units of measurements
Here we discuss the units which are related to alignment jobs.
1 meter
1 inch
1mm
1mm
1 inch
1mm
1micron

= 100 Centimeter = 1000 millimeter

= 2.54 Centimeter = 25.4millimeter
= 0.0393 inches
= 1000 microns
= 1000mils
= 39.37mils
= 0.0393mils

What is rotating equipment and its construction

Equipment that moves liquids, solids or gases through a system of drivers (turbines, motors, engines), driven
components (compressors, pumps), transmission devices (gears, clutches, couplings) and auxiliary equipment
(lube and seal systems, cooling systems, buffer gas systems

Rotating equipment mainly have drive or driven shaftwhich is tranmitting the

power and holding all the rotating elements such as, impeller,fan,turbine blades
etc..,. Shaft is supported by the bearings. Couplings are used to connect two
shafts.
Now we can discuss about the bearings

Rotating shaft is supported by bearings at both ends.

The loads acting on the shafts.

Radial load means the load applied vertically to the shaft
Thrust load or axial load means the load acting parallel to the Shaft axis.

Bearings
The function of bearing is to support and control the motion of rotating shaft at a
minimum consumption of power

Bearings are broadly classified as

A. Plain bearings

B. Anti friction bearings

Plain bearings: Depends on a lubricating film to reduce friction between
shaft and bearing. Plain bearing develop tapered hydrodynamic oil film which
has tremendous load carrying capacity. These bearings are better for
supporting heavy loads and shock loads.

Plain Bearings classified on the basis of loading as

1. Journal bearing or Radial bearing
2. Thrust bearing
Journal bearing or radial bearing: Journal bearing is composed of two
Parts namely journal and bearing. Journal is that part of shaft,
Which runs in bushing. Bearing is in which the journal rotates. These
bearings are designed to take radial loads.

Thrust bearing: the bearing is designed to support an axial load. It is

loaded with axial forces, acting through the shaft end face. Vertical shafts,
Worm gears, helical gears etc. are subjected to axial loads and require thrust
bearing.

Anti friction Bearing: These bearings are made up of roller and ball
made up precision parts. These bearings will have line contact or point
contact. These bearings have rolling friction and this rolling friction is quite
low. These bearings require only small amount of lubrication. At high speeds
lubrication becomes difficult due to tendency of rolling elements throw of
lubricant. These are sensitive to vibration, poor fits, corrosion and abrasive
dirt.
Anti friction bearing Parts:
1. Inner ring (inner race)
2. Outer ring (outer race)
3. Separator
4. Ball
These bearing inner race fits on shaft and outer race fits into the bearing
housing. The inner ring is force fit on shaft and outer ring is push fitted in the

bearing housing. A cage is used to keep the balls or rollers uniformly

distributed around the circumference.

When the shaft rotates in bearing the inner race of the bearing rotates with
the shaft. The balls or rollers roll in between the inner and outer race. The
friction takes place between inner race, outer race and the balls or rollers.
This friction is very low because as in the case of ball bearing there is a point
contact and in case of a roller bearing there is a line contact between the
rolling elements.

Anti friction Bearings classified into two main types:

1. Ball bearing
2. Roller bearing

The common types of ball bearings are the following

Deep groove ball bearing it will take radial load.

Self aligning Ball bearing it takes radial load as

well as slight misalignment

Angular contact ball bearing --- it takes radial load as well as thrust load at
One direction.

The common type of Roller Bearings

Tapper roller bearing--- it will take large

radial load and some application it will take
axial load also.

Spherical roller bearing ---- It takes large Radial loads and takes
Misalihnment.

Couplings.
Coplings are used to connect the driver and driven shafts for power transmission.
The main parts of the coupligs are Hub, spacer ,flexible element(only in flexible
coupling) and bolts.
The coupling type and size are designed according to the power tranmission, the
operation condition of the equipments,

Coupling safety:
1) Take more care during coupling mounting , dismantling and spacer
installations time.the face, Rim should not be damged.
2) Use correct size coupling bolts .
3) Care your fingers during installation.
4) Dont use steel hammer to remove the coupling spacer. Use correct tools.
5) Always maintain correct DBSE(Distance Between the Shaft End) as mentioned
in the equipment manual.
6) The coupling guard should be installed immedeitly after the copling
installation and check before run the machine.
Type of couplings:
Rigid
Most common in large steam turbine-generator units and large vertical
pumps
Flexibility is from connected shafts
Flexible
Most common for general process machinery such as: motors, gears,
pumps, compressors, fans and blowers
Flexibility comes from sliding or flexing of coupling element.
Flexible coupling
Transmit power

 Reduce bending and axial stresses from misalignment and thermal growth
Control torque transmitted between shafts
De-couple vibration response between shafts

VERNIER CALIPER

Parts of a vernier caliper:

1. Outside jaws: used to measure external diameter or width of an object
2. Inside jaws: used to measure internal diameter of an object
3. Depth probe: used to measure depths of an object or a hole
4. Main scale: scale marked every mm
5. Main scale: scale marked in inches and fractions
6. Vernier gives interpolated measurements to 1/10 mm or better
7. Vernier gives interpolated measurements in fractions of an inch
8. Retainer: used to block movable part to allow the easy transferring of

Instructions on use

The Vernier caliper is an extremely precise measuring instrument; the reading

error is 1/20 mm = 0.05 mm.

Close the jaws lightly on the object to be measured.

If you are measuring something with a round cross section, make sure that
the axis of the object is perpendicular to the caliper. This is necessary to
ensure that you are measuring the full diameter and not merely a chord.

Use the bottom scale, which is in metric units.

Notice that there is a fixed scale and a sliding scale.

The boldface numbers on the fixed scale are centimeters.

The tick marks on the fixed scale between the boldface numbers are
millimeters.

There are ten tick marks on the sliding scale. The left-most tick mark on the
sliding scale will let you read from the fixed scale the number of whole
millimeters that the jaws are opened.

In the example above, the leftmost tick mark on the sliding scale is between
21 mm and 22 mm, so the number of whole millimeters is 21.

Next we find the tenths of millimeters. Notice that the ten tick marks on the
sliding scale are the same width as nine ticks marks on the fixed scale. This
means that at most one of the tick marks on the sliding scale will align with a
tick mark on the fixed scale; the others will miss.

The number of the aligned tick mark on the sliding scale tells you the number
of tenths of millimeters. In the example above, the 3rd tick mark on the

sliding scale is in coincidence with the one above it, so the caliper reading is
(21.30 0.05) mm.

If two adjacent tick marks on the sliding scale look equally aligned with their
counterparts on the fixed scale, then the reading is half way between the two
marks. In the example above, if the 3rd and 4th tick marks on the sliding
scale looked to be equally aligned, then the reading would be (21.35 0.05)
mm.

On those rare occasions when the reading just happens to be a "nice"

number like 2 cm, don't forget to include the zero decimal places showing the
precision of the measurement and the reading error. So not 2 cm, but rather
(2.000 0.005) cm or (20.00 0.05) mm.

THE MICROMETER

The micrometer is a precision measuring instrument.

Each revolution of the ratchet moves the spindle face 0.5mm towards the anvil face.
The object to be measured is placed between the anvil face and the spindle face.
The ratchet is turned clockwise until the object is trapped between these two surfaces and the ratchet
makes a clicking noise.
This means that the ratchet cannot be tightened any more and the measurement can be read.

EXAMPLE MEASURE READINGS

Using the first example seen below:

Read the scale on the sleeve. The example clearly shows12 mm divisions.
Still reading the scale on the sleeve, a further mm (0.5) measurement can be seen on the bottom half of the
scale. The measurement now reads 12.5mm.
Finally, the thimble scale shows 16 full divisions (these are hundredths of a mm).
The final measurement is 12.5mm + 0.16mm = 12.66

DIAL INDICATORS

Dial indicators are used in many types of service jobs. They are particularly useful in
determining run-out on rotating shafts and alignment.

Run-out is the side-to-side variation of movement when a component is turned.

Dial indicators normally have two separate scales.

The needle is able to move numerous times around the outer scale. One full turn may
represent 0.1" in inch scale dial and 1 mm in metric system dial.

The small inner scale indicates how many times the outer needle has moved around its
scale.

In this way, the dial indicator is able to read movement of up to 2" or 1cm.

Dial indicators can measure with an accuracy of 0.001" or 0.01mm.

They must be fitted so that there is no movement between the dial indicator and the
component to be measured.

Most dial indicator sets contain various attachments and support arms so they can be
attached to the component..

When attaching a dial indicator, keep support arms as short as possible.

Make sure that all attachments are tightened to prevent unnecessary movement
between the indicator and the component.

Make sure the dial indicator pointer is positioned at 90 to the face of the component to
be measured.

Always read the dial, face or straight on. A view from the side can give a considerable
"parallax" error. Parallax error is a visual error caused by viewing measurement markers
at an incorrect angle.

The outer face of the dial indicator can be moved so that the zero can be positioned over
the pointer.

How to install and read the dial indicator?

Select the correct gauge and attachment

Select the gauge type, size, attachment and bracket, which fit the part youre measuring.
Mount the dial indicator on a firm surface to keep it still.

Ensure plunger is at 90 degrees

Adjust the indicator so that the plunger is at 90 degrees to the part youre measuring.

Study the face of the dial indicator. Look the values of the increments listed on the face of
the indicator.
Most metric dial indicators utilize 0.01 mm or 0.02 mm increments.
Set any whole number (not in fraction) in smaller dial by adjusting the dial indicator
fixture.
Normally set 6". Adjust the larger dial indicator to zero and lock the dial.
Now initial reading is 6.0mm.
Just slightly lift the plunger up and slowly release. During this time observe the larger
needle move away from zero and return back to the original position. It should be again
align with zero, otherwise check the fixture and adjust.
Measure an object normally by rotating the dial fixture or the object.
Observe the larger dial on the indicator. If the indicator moves clockwise note the reading
as positive(+). If it moves anti clockwise note the reading as negative(-)
Record the value of the number the dial points to.
Example..,If the dial points to 15, the value would be 0.15 mm if the indicator uses 0.01 mm
increments,
Or 0.30 mm if the indicator uses 0.02 mm increments.
Observe the number the smaller dial points to on the smaller scale.
This number represents the number of times the larger dial made one full rotation around the
face of the indicator. Calculate the value represented by this number. If the indicator uses
100 0.01 mm increments around its face, each rotation of the smaller dial represents 1 mm.
So if the smaller dial points to the number 6, this represents 6 mm worth of larger dial
rotations.

Add together the values shown by the large and small dials. Using the previous numerical
examples and 0.01 mm increments, the 6 registered by the smaller dial and the 15
registered by the larger dial add together to create a final measurement of 6.15 mm. If the
indicator used 0.02 mm increments, the measurement would be twice that amount.

INSTALLATION OF THE ROTATING EQUIPMENT

Generally the equipment and driving motor are mounted on the steel fabricated frame.
Before installing the pump frame,

Inspect the equipment condition. If you found any damage, repot immediately.
Inspect the pump support frames welded on the deck plate. Check level and orientation as
per the supplied drawings.
Mark the support where the equipment frame will be correctly placed as per the drawing.
Remove the paint on the edges where the equipment frame matches and also remove paint
in frame edges also for welding.
Immediately apply anticorrosive coat on the surfaces where painting was removed.
Install the equipment frame on supports and align the frame edges matching to the marking.
Using MASTER LEVEL check the levelness of the pump frame in longitudinally and
transversely. Place the master level in machined surface of the equipment frame as shown
on the drawing.
The level should be within 200 micrometer per meter length(0.002 inches per feet)
Using frame jack screws we can adjust the level.
If the pump is in parallel as design (example Q-47-G- 025 A , Q-47-G- 025 B) both are
should be in same level. Both pump discharge nozzle should be in same elevation level.
Fill the gap if any between the pump base frame and supports with metal plates or shims.
First tack weld in opposite directions, alternatively between the frame and supports.
Again one time check the level of the pump.
After completion of direction control department checkup, weld the frame with support.
During welding dont weld in the same side continuously. If one side corner start welding just
weld for
150 mm length .Then diagonally opposite side weld for the same length. Then
continue with other corners.
Final weld we can weld continuously in all direction.
During the welding, ensure the levelness continuously.

PIPING WORKS WITH PUMPS

The strain of the pipes connected with pump discharge and suction flange also will affect the
alignment. So we have to maintain the flange gaps, parallelism as per standard API 686.
The following tolerance will help as to maintain the pump stress free from the piping.
To check the parallelism and gap use feeler gauge. And measure at clock positions 12O
clock, 3O clock, 6O clock and 9O clock.
Gap will be varying with the size of the gasket.

Flange Face parallelism

If flange diameter below 300 mm - 0.2 mm tolerance allowed.
300mm to 600 mm - 0.3mm
Above 600 mm

- 0.5mm

Bolt hole offset tolerance

The bolt holes of the parallel flanges should be align correctly the maximum tolerance of bolt
hole offset in any direction is 1.5mm.
If above tolerance not achieved, we can rectify with the piping department before hydro test
and reinstating works.
How to check the pipe stress on our equipment?
After completion of the piping work, disconnect the suction and discharge flanges.
Remove the gaskets also and ensure the gap between the flanges.
Check the gap and parallelism between the flanges.
Fix the dial indicator fixture with motor shaft. And place the dial indicator tip, one in
top and another in side of the pump coupling.
Set zero in the dials.
First start with any one flange let we start from, suction flange.
Tight the bolts by sequence for example if required torque is 100 lbft, first tight up to
50 lbft.
Then tight up to 100lbft.
Now check the dial gauge readings. If it is within .05mm (50 microns) the pipe strain
is acceptable. If it is more than the limit with help of piping department rectify the
problem.

What is the shaft alignment in rotating equipment?

The alignment means to bring both equipments shafts central axis in one line .
Good alignment will increase the life of the equipment.
Bad alignment will damage or reduce the parts of the equipments bearings, mechanical seal,
couplings,
Internal clearance etc.,

It will damage lube oil seals and cause lube oil leak. Because of rubbing or overload of the bearings
and
other rotating parts, The temperature and vibrations of the equipment will
increase.

Type of misalignment
Generally the misalignment of the equipment shafts to be coupled as below.
1) Parallel misalignment
2) Angular misalignment

Based on this we measure the misalignment as below

Parallel Vertical offset (Radial top and bottom difference)

Parallel Horizontal offset(Radial horizontal side out difference)
Angular Vertical gap(Angular top and bottom difference)
Angular Horizontal gap(Angular-side out difference)

Parallel misalignment - The distance between the shaft centerlines in vertical

plan and in horizontal plan
The vertical difference, we can make it correct by adjusting the shim under the
motor legs. The horizontal difference, we can adjust by moving in the side ways of
the motor.
Angular misalignment- The angle difference between the shafts in both vertically
and horizontally.
In vertical plane we can make it correct by adjusting shims and in horizontal by
moving the motor diagonally.

Type of alignment methods.

1. Rim and face method
2. Reverse dial indicator method
3. Laser instrument method

PRE-ALIGNMENT CONDITIONS
Prior to any alignment activity an extensive list of items must be checked to ensure acceptable
results. The obvious item involves ensuring that the machine shaft axes are roughly aligned
within 50 mils. Other inspections should include:
1. The foundation base plate is adequate and that grout has been installed
properly.
2. All machine feet are in full contact with the foundation base plate or supports.
3. Piping is not inducing strain onto the machine cases. Piping should be aligned
to within " of their flanges.
4. The machine feet bolt holes have enough clearance to conduct alignment
activity.
5. The coupling faces are axially aligned; the axial spacing between the coupling
faces as correct.
6. Coupling radial run out is less than 2 mils.
7. Coupling face run out is less than mil.
8. The moveable machine has as initial shim pack installed; the shim pack
should be comprised of one thick spacer and one or two smaller shims. Too
many shims will act like a spring causing additional problems.
9. The required amount of cold offset compensation is available; this may be
available from the machine manufacturer.
10.The alignment bracket is appropriate to the activity required.

Rough Alignment and Coupling Gap Setting

Before checking the Coupling Gap, roughly align the couplings by using Straight
edge and feeler Gauge.
For more Spacer length coupling , we can check with Straight edge.
Place the Straight edge on both coupling topside in same time as shown in the
Figure.
Now we can visually see the difference in height of the couplings. According to this
we can adjust by adjusting shims under the motor legs. Same we can follow for
horizontal Side out adjustment.

For less coupling gap we can use Taper gauge or Feeler Gauge as shown in the
figure.
We can get roughly the difference between the couplings, vertically and horizontally
and can adjust the alignment.
Reference with coupling drawing or General arrangement Drawing or from
installation Manual, we can get the DBSC
(Distance between the shaft ends). By using inside micro meter check the DBSC.
The tolerance is +/- 0.25mm.
If not achieved, adjust the motor. For Hot alignment it may differ. We will discuss
later, separately.

Soft foot

Soft foot is a condition in which one of the feet does not sit flat on the base. The foot or the
base may have been warped. When you tighten the bolt on the foot, the machinery will
distort.
If the soft foot is not corrected before the alignment, the alignment reading will vary in every
rotation and will show fault result.
There are two type of soft foot. Parallel and Angular as shown in the figure. For example all 3
legs of the motor are equal in height but 4th one short or more in height, the motor will not
sit on the base properly. That is Parallel soft foot.
If all heights are same but the particular legs contact with the base is not properly sit, only
some portions only contact with the base is called Angular Soft foot.

How to check the soft foot

Remove all dirt, rust and burns from the bottom of the machine feet
Set the machine in its place, but dont tighten the hold-down bolts.
Take very minimum size of the feeler gauge leaf and try to pass between
the feet and base. If it easily passes, try with another bigger size of feeler
gauge leave.
If it passes in between the base and feet. We can assume that there is soft
foot. And also we have to check from all corners of the feet.
If it is not passes from one side and pass from another side means we can
assume that is angular soft foot. According to the gap we can place the
small piece of shim or stepped shim under the feet.
Check the same with all foot (legs) of the machine and correct the angular
soft foot.
Finally tight all the hold down bolts
Secure the dial indicator holder on the base. Place the dial indicator tip on
the feet vertically and set zero in the dial.
Loose the hold down bolt of the particular feet only and watch the
movement in the dial. Record the final reading.

If the feet raises from the base while loosening the bolt, that is the soft foot
,equal to the amount of deflection shown on the dial indicator. We can
place the equal amount of shim under the feet.
Re tight the bolt again and repeat the process again until there is no
movement in the dial indicator.
Repeat this procedure to all remaining feet to correct the soft foot.
Remember, while a selected foot is being checked for soft foot, the
remaining foot must be in tightened.
reeeeee

RIM AND FACE METHOD ALIGNMENT

For smaller coupling spacer length, we can use this method.

The Dial indicators are positioned as the above drawing. One dial placed on the Face
and another one placed on the Rim of the coupling hub. Generally some standard
readymade brackets are available in the market for fixing the Dial indicators. In
some cases we can fabricate the bracket also. We have readymade bracket supplied
by PETERSON ALIGNMENT TOOLS.

First we should install the bracket firmly on the stationery machine and
position the indicators on the face and rim of the other coupling hub which is
going to align.
Ensure the dial indicators are perpendicular to the point where it is
positioned. And ensure the indicators are in 12 o clock positions.

Set Zero in the dials and just turn both shafts slowly in full round and bring
back to the same 12o clock position. And check the dial again. If it is in same
Zero, the bracket installation and dial indicators, soft foot of the motor allare
in good condition. Otherwise we have to check one by one to rectify the
problem.
Measure the following dimensions before alignment.
H = 2 X the face dial indicator position on the hub from the centre line)
D= The distance between the Face of the Coupling Hub to the first leg of
the motor
E= The distance between the Face of the Coupling Hub to the Second leg
of the motor
Bring the dial indicator position to 12o clock position and set Zero in both
dial. Then slowly , simultaneously, parallel rotate the shaft in the direction of
rotation of the machines (example clockwise) up to 90
(if rotate in clock
wise, its 3o clock position). Note the readings in both dial and write
separately. For radial, note as R90. For angular, note as F90.
Continue the rotation and note the readings at 180. Note the readings as
R180 and F180. Same way note the readings at 270 as R270 and F270.
Return to top side that is 0 position and ensure the dial readings shows
zero.
For example,
H = 12, D10, E=48
R90 = 12, R180 =21, R270= -3
F90 = 11, F180 = -6, F270= -17

From the readings we can understand the misalignment as

Radial top and bottom difference = (R180-R0)/2 = (21-0)/2 = 10.5mils
(Motor is
21mils down than the pump)
Angular top and bottom difference = (F180-F0)/2 = (-6-0)/2 = (-3) mils
(Motor
back side leg elevation is higher than front side)
Radial horizontal difference

= (R270 R90)/2 = ((-3)-12) /2 = (-7.5) mils

Angular horizontal difference

= (F270 F90)/2 = ((-17)-11)/2 = (-14) mils

To find out the shim plate adjustment

For vertical plane

VERTICAL NEAR FOOT SHIM AMOUNT (VN) =

F 180
+ D
( R 180
2 ) ( ( H ))
If results comes in positive (+), add shim. If it is negative (-) remove shims.
For Horizontal plan, looking from stationery equipment, if result is in positive (+),
right (towards you in Vertical plan. If it is in negative (-),left ( away from you in
Vertical plan).

HORIZONTAL NEAR FOOT ADJUSTMENT (HN) =

R 270R 90
F 270F 90
+D
2
H

HORIZONTAL FAR FOOT ADJUSTMENT (HF) =

From our readings,
For Nearest foot (VN) shim adjustment = (21/2) + (10 x (-6/12)) = +5.50 mils (Add
shim)
Far foot (VF) shim adjustment
(Remove shim)

= (21/2) + (48 x (-6/12)) = (-13.5) mils

Horizontal near foot adjustments

Nearest foot (HN)
mils (Away from you)
Far foot (HF)
-119.5mils (Away from you).

= ((-3)-12/2))+(10 x ((-17)-11/12) = -30.8

= ((-3)-12/2) + (48 x ((-17)-11/12)=

REVERSE INDICATOR METHOD

For larger coupling spacer length Reverse Indicator method is suitable to measure
and correct the misalignment.
The dial indicators are only positioned on the coupling rims. One bracket is attached
with driver and its indicator placed on the driven coupling rim. Same from driven to
driver also placed as shown on the figure.

Ensure all the brackets are attached firmly without shack.

From pump to driver, dial is on bottom of the driver coupling(example this
drawing) and driver to pump dial indicator on top of the pump coupling rim.
SetZero on both dials and rotate slowly on the same direction of rotation of
the machine. Ensure after one full rotation completed, both dials are in same
zero position. If not correct it as we did for Rim and Face Method.
Take the following measurement before the alignment.
C - the distance between the dial indicator plungers.
D - The distance between the indicators (on motor coupling) to the first leg
of the motor
E - The distance between the two motor legs
FThe distance between the indicators on the pump coupling to the first
leg of the pump
G - The distance between the two legs of the pump
X - One half of the driver rim reading difference (from top to bottom or side
to side in mils)
Y - One half of the driven rim reading difference (from top to bottom or
side to side in mils)
Rotate the both shafts slowly and note the reading at every 90intervals.

Now we can directly apply all the readings and data in the following formula
to get the correction.

{(

Outboard feet of Driven =

{(

Inboard feet of Driven

{(

F +C )( X+ Y )
(Y )
C
2

G+ F +C )( X+ Y )
(Y )
C
2

C+ D ) ( X +Y )
(X)
C
The disadvantage
of traditional
alignment
Inboard
feet of
Driver method.
=
2

straightedge/feeler gauge methods

The straightedge/feeler gauge methods which depend on the limited resolution of the human eye, produce
a resolution of 1/10 mm (0.004"). This is far too inaccurate for most machines.
Dial gauges
Although dial gauges have a resolution of 1/100 mm (0.0004"), calculations tend to be complicated, and
users must be highly experienced.
How accurate are dial indicator readings?
Sagging indicator brackets
This should always be measured before actual alignment reading are taken irrespective of how solid the
bracket appears.
Low resolution
Up to 0.005 mm rounding error may occur with each reading for a total of up to 0.04 mm error in values used for result calculations.
Sticking/jumping dial hands
Sometimes the gauge must be tapped in order for the indicator needle to settle on its final value (which
may still not be the correct one).

Play in mechanical linkages

Slight amounts may not be noticed, yet produce large errors in results.
Reading errors
Simple human errors that occur all too often when dials must be read under cramped, poorly-lit conditions
and severe time constraints.
Tilted dial indicator
The gauge may not be mounted perpendicular to the measurement surface so that part of the
displacement reading is lost.
Axial shaft play
This can affect face readings taken to measure angularity unless two axially mounted gauges are used

Laser alignment

Laser instruments are working by using the laser beam light. When laser beam
emitted from transducer as straight line, hit the reflector (Roof Prism) and return
back to transducer by 180. The measurement of variation of the returning beam is
already calibrated. So we can get the offset of the shafts.

First read the operating manual for proper usage. It will differ from one model
another model
Install the brackets firmly and rigidly.
Install the transducer which emits laser beam in stationery shaft and reflector
in movable machine shaft.
As per the operating manual instruction centre the laser beam.
Enter the data whatever displayed in the screen.

As per operating manual instruction check the soft foot and correct it.
Turn the shaft and measure the misalignment.
Correct the misalignment as displayed in the screen.

Advantages of laser instruments.

Error free and accurate measurement: No human uncertainties, no bracket sag influence
and no reading errors

Straightforward alignment procedure: System can be used by any operator

Quick on-screen laser beam adjustment

Universal precision brackets designed for quick and rigid set-up

Automatic computation of horizontal and vertical coupling and foot values Clear
graphical representation of the machines with the corresponding foot correction value and
direction "Live move" shows updated values and the direction of the correction. Reports
generated directly from instrument.

Hot alignment
When rotating equipments are in operation, due to the operating conditions, the
temperature of the entire machine will increase. According to the metal property all
the metal will expand certain amount in all direction due to temperature.
It will differ from machine to machine. The designer and manufacturer already
analyze the operation condition of the equipment and calculate the thermal growth.
The shaft also the part of the machine and directly expose internally in the
operating condition will expand in axial and radial direction. When we do alignment
in cold and shutdown condition of the machinery, there is no such thermal growth.
Generally we maintain the standard coupling gap and align the shafts as both
centers are in one line.
But during operation the conditions will change. As said above due to thermal
expansion, the perfect alignment of the shafts will be changed. For overcome this
problem we have to consider the maximum growth of the shafts as per
manufacturer recommendation. We should align the shafts in cold condition to the
value of thermal growth condition. When the machine comes in operation condition
automatically we can achieve perfect alignment what we required.

For example the manufacturer recommends that the thermal growth of the shaft is
0.35mm and axially and 0.09mm in radial direction. As per the coupling drawing
DBSC (distance between shaft ends) is 150mm.
We have to maintain the DBSC as 150 + 0.35 = 150.35mm in cold condition. And
align the shaft 0.09mm down.
When the machine runs and attained the operating temperature, due to thermal
growth both shaft grow inside 0.35mm that means now the DBSC is 150.35-0.35 =
150.0 mm what we required as coupling drawing. The shaft also will grow in radial
0.09mm from the bottom and will align with the centre line correctly.

Offset Alignment

In large heavy machineries, shafts are supported by plain or journal bearing. For this
bearing lubrication, the it has the clearance with the shaft. The shaft always sit on
the bottom in cold condition and both centers are in offset. During starting of the
machine the lubrication oil will enter into the clearance by external pressure or by
the wedge action. The oil force will lift the shaft and maintain uniform oil layer
between the bearing and shaft. Now the shaft centre coincides with bearing centre.
When we do the alignment in cold condition if we correct the shaft in zero position
with the other shaft, during running due to lubrication pressure further it will lift the
shaft and cause misalignment.

We have to consider this in the alignment in cold condition. As the manufacturer

recommendation the bearing clearance we have to take in alignment account.
For example if the clearance of the bearing is 0.15mm, in cold alignment time we
have to position the shaft at 0.15mm down from centre line that means the top and
bottom reading should be + 0.15mm. when the machine starts rotating, the oil will
enter between the shaft and bearing and bring the shaft center to bearing centre
which we required.