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SHAFT ALIGNMENT

Objective

To study and research shaft alignment and its parameters

Alignment Definition

Shaft alignment is a process in which machines can be positioned in a manner that when transferring

power from shaft 1 to shaft 2 the rotation axes of these shafts are collinear as the machine is running at its

normal conditions. An example of machines which need shaft alignment is the motor and hydraulic pump.

The exception to this definition is the gear coupling which requires some degree of misalignment to

ensure sufficient lubrication when in operation.

Figure 1: shaft alignment.

Alignment Measurement.

Shaft alignment has to be measured and subsequently corrected, and therefore it is necessary to have a

method for quantifying and proofing alignment condition. The traditional method of shaft alignment is

by use of dial indicator. It is done by taking readings of the dial indicator at the coupling face or by

taking position values at the machine feet. The values obtained from both of these methods depend on the

dimensions of the particular machines. Since some various methods are used to mount dial indicators,

there is a likelihood of problems when comparing measurements and when applying tolerances. A more

convenient way is to describe the condition of shaft alignment in terms of angle, offset and a gap in the
vertical side view and horizontal plan view. By using this approach, there are four values which can be

used to describe alignment condition.

Figure 2: angularity a.

Angularity is used to describe the angle between the two axes of rotation.

Figure 3: angularity b.

Angularity can be described in terms of: degrees or mrads slope in mm/ m or thousandths/inch. This latter

approach is useful because the product of angularity and coupling diameter will result in an equivalent

gap difference on the rim coupling. Thus the angle is oftenly described in gap per diameter. The gap

itself becomes more meaningful when divided by the diameter. This diameter is oftenly referred to as

working diameter and sometimes known as coupling diameter. Any value convenient can be used as the

working diameter.
Figure 3: working diameter, gap and angle relationships.

For a 152.4 mm coupling which is open at the top by a value 0.127 mm will give angle of 0.83 mrads.

For a working diameter of 254 mm the corresponding gap will be 0.21082 mm.

For working diameter of 100 mm the corresponding gap will be 2.1082 mm

Figure 4: relationship of gap and angle.

The distance between rotating axes at a given point is known as the offset. As illustrated in the following

figure, the offset value will vary depending on the location at which the distance from one shaft rotation

axis to the other is measured. Off set can also be determined in mm or thousandths inch at the center of
coupling if there are no further instructions given. This definition is applicable to the short flexible

couplings but for spacer couplings the offset is determined at the coupling power transmission planes.

Figure 5: offset variation with location.

Short flexible couplings

These are the couplings in which flexible element axial length is equal or smaller than diameter of

coupling. Because the alignment entails combination of offset and angularity, then it is necessary to

correct the machine in both horizontal and vertical planes to obtain four values which are essential for

defining the alignment condition. These values are:

Vertical angularity also known as the gap/diameter.

Horizontal angularity also expressed as gap/diameter.

Vertical offset

Horizontal offset.
Figure 6: sign convection and notation.

Spacer shafts

These are the shafts used in a when significant alignment variations are expected during machine

operation for instance as a result of thermal growth. Angular change which occurs at the end of the spacer

shaft will be small through the spacer shaft length. Four angles are necessary when describing the

alignment condition. These angles can be determined by measuring the angle existing between the axis of

rotation of the spacer shaft and axis of rotation of the respective machine. These angles are:

i. Vertical angle
ii. Horizontal angle
iii. Vertical angle

iv. Horizontal angle


Figure 7: sign convention and notation

Alternatively, the alignment can be determined by applying offsets:

i. Vertical offset B

ii. Horizontal offset B

iii. Vertical offset A

iv. Horizontal offset A

The above offsets are determined between the axes of rotation of the machine shaft at the end of the

spacer shaft location.


Figure 8: sign convention and notation

The following diagram illustrates the relationship between various angles and offsets.

Figure 9: relationship between angles


Dial indicator methods of Shaft and coupling alignment

1. Rim and face methods

a) Trial and error method.

Trial and error method is used where shaft float and bracket sag are ignored. It is done by rotating one

shaft during the measurement which adds more errors to the alignment resulting from run-out of coupling

and bending of shaft.

Figure 10: trial and error method.

The machine coupling is clocked using the rim and face indicators. The indicators ae set to 12 oclock and

the machine shaft to be aligned is perpendicularly to make a half turn to the 6 oclock position. The

nearest foot to the coupling is either lowered or raised by a given amount which is equal to half reading of

the indicator reading. Shims are placed repeatedly far from the coupling under the foot up to a time when

the face indicator readings remain unchanged when the shaft is rotated. Similarly, at 3 oclock position

the indicators are zeroed and then rotated to the position of 9 oclock for horizontal correction. This

method is inefficient as it results to significant errors at the planes of the transmission coupling.

b) Calculation method.

The device used to measure alignment is a dial indicator. The device points or indicates on the dial face

the increments marked. By pushing the foot in to the body enables the dial to rotate in clockwise

direction. The total number of indicator marks made by the hand is equal to the distance that the hand
travelled while it was pushed into the body. Similarly the dial indicates the same travel distance when the

foot travels out of the body. When the foot travels in there is positive dial count and negative dial count

when it travels out.

Figure 11: traditional indicator set up.

After finishing mounting, the shafts are rotated together and then the dials reading are read at position

12:00, 6:00, 3:00, and finally at position 9:00. Formulas for calculating alignment corrections

R 6 R 0 RS
VO
2
F6 F0
VA
Dia
R9 R3
HO
2
F9 F3
HA
Dia

Where:

RO-rim reading at position 12 of oclock

R3-rim reading at position 3:00 of oclock

R6-rim reading at position 6:00 of oclock

R9-rim reading at position 9:00 of oclock


F0-face reading at position 3:00 of oclock

F3-face reading at position 3:00 of oclock

F9-face reading at position 9:00 of oclock

Dia-circle diameter travelled by the face indicator.

RS-rim indicator sag

FS-face indicator sag

S-span between measurement plane and machinefoot.it is either a negative or positive value.

The clockwise is given by looking in the direction along shaft from MTBM to STAT.

Shim= (VA) (s)-VO

( F 6 F 0 FS ) *s R0 R6 RS
Shim
dia 2

Move = (HA) (*s)-HO

( F 9 F 3) *s R3 R9
Move
dia 2

The position of dial indicators at 12:00 is set to zero and read at 6:00, the shim calculations will be:

( F 6 FS ) * S R6 RS
Shim=
dia 2

If the result is positive then more needs need to be added while if the result ids negative then it means

remove shims. By setting the dial indicators to zero at position 3:00 and then reading at position 9:00 the

calculation for the move will be:


F 9 * S R9
Move = .
dia 2

If the result is positive it means that move towards position 3:00. If the result is negative it means move

towards position 9:00. The sum of the readings at 3 and 9 oclock should be equal to sum of the readings

at the 12 and 6 oclock readings. The major source of error in this method is the spanner bar slag. It can

cause misalignment of the machine shaft. To compensate for the slag, it is measured and then it is added

to the slag reading to the position 6:00 readings.

2. Reverse indicator methods

a) Calculation method.

This is the most advanced method of indicator shaft alignment. The American petroleum institute

recommends this method as the preferred indicator alignment method.

Figure 12: traditional reverse indicator set up.

After mounting, the dials are read at 12:00, 3:00, 6:00 and 9:00 when the rotating shafts are rotated

simultaneously. The misalignment at the center of coupling is determined using the following formulas.

0.90
0.45mm
2

Where:
SO= reading of the left rim at position 12 oclock

S3= reading of the left rim at position 3 oclock

S6= reading of the left rim at position 6 oclock

S9= reading of the left rim at position 9 oclock

M0= reading of the right rim at position 12 oclock

M3= reading of the left rim at position 3 oclock

M6= reading of the left rim at position 6 oclock

M9= reading of the left rim at position 9 oclock

D= distance between right and left indicators.

C= distance between coupling center and left indicator.

SS = left rim indicator sag (1)

MS= right rim indicator sag (1)

The corrections for the right machine feet are calculated as follows:

Right feet shim = (VA-sR) VO

Left feet shim = (VA-sL) VO)

If the result is positive add shim and if negative it means you need to remove shim.

Left feet shim= (VA-sL) VO.

Right feet shim = (VA-sR) VO.


For positive results move towards position 3 oclock and for negative results move towards position 9

oclock.

sL=distance between coupling center and left feet of right mce

sR = distance between coupling center and the right feet of the mce

Setting the dial indicators to zero at position 12 oclock and reading at position 6 oclock the calculations

for the shim are as follows:

HO
S 9 S 3 (S 9 S 3 M 9 M 3)* C
2 2D

HA
S 9 S 3 M 9 M 3
2D

Shim left feet


S 6 S 3 M 6 c sL S 6 SS
2D 2

Shim right feet


S 6 S 3 M 6 M 3 c sR S 6 SS
2D 2

For positive results shim is added and for negative results shim is removed.

Setting the dial indicators to zero at position 3 oclock and then reading at position 9 oclock the

calculations for the move are as follows:

move left feet


S 9 M 9 c sL S 9
2D 2

move right feet


S 9 M 9 c sR S 9
2D 2

When the results are positive then move towards position 3 oclock and for negative results move towards

position 9 oclock.
b) Graph method.

In this method a graphical solution is used to avoid numerous mathematical computations and help

engineers resolve alignment problems and to achieve move and shim corrections.

Figure 13: reverse indicator configuration.

Figure 14 a: example (all values are in mm).

Indicator sag bracket= -0.10 mm.

For bracket sag the total indicator readings (TIR) after correction are:

Figure 24 b.
Values for the true shaft offset are obtained by dividing the TIR values by 2.

0.70
Offset S= 0.35mm -
2

1.40
Offset M= 0.70mm .
2

The following is a graph of the offsets.

Figure 14 c: graph 1.

The right machine is the machine to be moved (abbreviated as MTBM). At position 12 oclock both

indicators are set to zero. The view direction is from MTBM to the machine at rest. The shaft needs to be

rotated through angle of 1800 in the same direction as the normal shaft angle of rotation. The dial

readings are taken and recorded. The following example can be considered:

Figure 14 d.
TIR values are divided by 2 in order to calculate the true offset values of the shaft in the dial indicator

planes.

0.50
Offset S= 0.25mm
2

0.90
Offset M= 0.45mm
2

The offset values are then plotted in a graph as shown below.

Figure 14 e.

Measurement bracket sag

The amount of sag is measured by mounting the entire fixtures on a straight pipe. The fixtures are

adjusted until the distance between the brackets is the same as when they will be mounted on the

machine. Also the indicators need to be positioned the same way they will be mounted on the machine.

When the indicators are held at position 12 oclock the dials are zero. The pipe is then rotated until the

indicators are at position 6 oclock. The readings are taken and recorded.
Factors considered before alignment of shaft and coupling.

1. Indicator bracket sag-this factor should be determined before actual shaft alignment readings are

done irrespective of how the bracket appears solid.

2. Internal friction/hysteresis: this is necessary because sometimes the gauge needs some tapping to

help the needle of the indicator to deflect to its final value.

3. Readings errors-errors can occur for example when readings are taken under difficult conditions

or under severe constraints.

4. 1/100 mm resolution-rounding error of up to 0.005 mm can occur when taking the readings. The

error can be reduced by compounding the reading several times.

5. Mechanical linkage play-slight plays in linkage may end up resulting in reading values with

errors.

6. Axial shaft play- this factor will alter the face readings recorded to determine angularity unless

the engineer uses two axial gauges are used.

7. Titled dial indicators-sometimes reading is lost when the gauge is not perpendicularly mounted to

the surface of the measurement.


Shaft straightness

A shaft is said to be straight in a given length when the distance variation of points from two

perpendicular planes to each other and parallel to the direction of the shaft remains in the specified

tolerance limits. Straightness tolerance can be used to control straightness of cylindrical surface, planar

surface and a center line or center plane. An axis is perfectly straight when all points of an axis are on a

straight line. Straightness control (u) shows by how much an axis of a certain part may vary from

reference ideal straight line. The following procedure can be followed to locate and inspect an axis

of a given shaft for the purpose of ascertaining straightness.

i. The part has to be placed in apparatus so that the ends of the part are held and allow

rotation of the part.

ii. On opposing sides dial indicators are mounted to locate median point.

iii. Make measurements of various angles at a given point x.

iv. Average of the median points for each angle is calculated to determine the center

point at point x.

v. The center points are used to plot graph in three dimensions to create the axis.

vi. If it is found that the axis is within the tolerance zone then it will be in the required

specifications.
Figure 15: straightness inspection.

Benefits of good alignment

Well aligned machinery will have many benefits. Some of the benefits are:

It increases operating life of plant and reliability.

It reduces cost of operation by reducing cost spare parts used like bearings and seals.

It improves plant production availability.

Reduces labour costs for maintenance.

There is no need of a standby plant.

There is reduced plant failure thus less production losses

There is improved safety in the plant


There is less power wasted by plant machinery

Improved insurance rates due to improved operating practices in the plant

Reference

1. http://www.engineeringessentials.com/gdt/straightness/straightness-axis.htm

2. An engineers guide to shaft alignment, vibration analysis, dynamic balancing and wear debris

analysis.

3. Toft, L., & Kersey, A. T. J. (1969). Theory of machines. London: Pitman.

4. http://www.maintenancetechnology.com/2002/12/understanding-shaft-alignment-basics.

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