Misalignment Effects Dan Nower PDF

Emerson Process Management - CSI Page 1 of 15
DoctorKnow® Application Paper

Title: Characterizing Shaft Misalignment Effects Using Dynamic Measurements
Source/Author:Dan Nower & Curt Thomas
Product: Corrective
Technology: Corrective
Classification:
CHARACTERIZING SHAFT MISALIGNMENT EFFECTS

USING DYNAMIC MEASUREMENTS
By Dan Nower, P.E. & Curt Thomas

Computational Systems, Incorporated
Biographies
Dan Nower is an Applied Development Engineer in the Engineering Division at Computational Systems,
Incorporated. He is responsible for the development of the alignment product line. Dan has over ten years
of alignment and vibration analysis experience. He received a BS in Mechanical Engineering from the
University of Missouri-Rolla He is a registered engineer in the state of Tennessee, an associate member of
ASME, has published several papers and is the holder of two alignment related patents.
Curt Thomas is a Consultant working with Computational Systems, Incorporated. He is responsible for
much of the testing of all alignment products. Curt has two years experience in the alignment area. His
prior experience includes steam turbine-generator repair work and a construction engineer in the U.S.
Army. He has a BS in Mechanical Engineering from the Georgia Institute of Technology
Abstract
A test system has been developed for measuring the effects of shaft misalignment under a variety of
common field conditions. This system allows five common types of couplings to be tested under loaded
conditions for both offset and parallel misalignment in the horizontal and vertical directions. The dynamic
measurements that were collected include vibration spectral and waveform data, axial and radial phase
data at 1x, 2x and 3x RPM, motor current data, and temperature data. This information should be
extremely useful when troubleshooting possible misalignment problems
Introduction
We all know the importance of proper shaft alignment. Misalignment can lead to excessive vibration and
stresses, premature component failures, and eventually shortened life spans of machines, Finding
misalignment while a machine is shutdown is not often difficult. Just measure the misalignment with a
reliable alignment system. But what about the step prior to this, when the machine is operating?
Most of us are familiar with the traditional vibration analysis rules:
1. 2x running speed amplitude
-Radial direction for offset misalignment

-Axial direction for angular misalignment
-Most misalignments are a combination of the two, so 2x in any direction
http://www.compsys.com/DRKNOW/APLPAPR.NSF/apweb/e015168db634c4b2852565a... 6/16/2010
2. 0° and 180° Phase Shifts
Radial direction for offset misalignment

Axial direction for angular misalignment
How accurate are these rules? Is the 2x RPM peak always a good indicator?. How does the coupling
design affect the shape of the spectral information? Do the phase rules work? If so, how much
misalignment does it take to cause the phases to shift?
Beyond the traditional rules, those that are involved in the alignment area have noticed interesting
phenomena with respect to motor current, and temperature. Little has been documented on these
parameters. This undertaking monitored these parameters, but this paper deals mainly with the accuracy of
the traditional rules on a limited number of couplings and touches briefly upon motor current and
temperature results.
Previous Work
Dewell, David L., "Detection of a Misaligned Metallic Disc Flexible Coupling Using Real Time Spectrum
Analysis." Master Thesis, Virginia Polytechnic Institute and State University, March 1980.
Lorenc, Jerome A., "Changes in Pump Vibration Levels Caused by The Misalignment of Different Style
Couplings." Proceedings, Eight International Pump Users Symposium, Houston Texas, March 1991.
Nower Daniel L., "Preliminary Report on Characterizing Shaft Misalignment Effects Using Dynamic
Measurements", Presented at the Vibration Institute Meeting, Wilmington, Virginia, June 1992.
Piotrowski, John D., "How varying Degrees of Misalignment Affect Rotating Machinery - A Case Study."
Proceedings, Machinery Vibration Monitoring and Analysis Meeting, New Orleans Louisiana, June 1984.
Test Machine & Couplings
The configuration of the test machine is shown in Figure 3. The motor drove the generator which provided
power to the heating element located below the motor. Much care was taken to correct for soft foot. The
couplings tested are listed in Table 1 along with their manufacturer's recommended alignment tolerances.
MOTOR: Dayton
1 Hp
3450 RPM Loaded, 3550 Rpm Unloaded
15 amps, full load
60 Hz, Single-Phase
115 Volts
28 Rotor Bars
24 Stator Slots
Anti-Friction Bearings
Loaded by heating element located underneath
GENERATOR: Dayton
360O RPM
16.7 amps, maximum
60 Hz, Single-Phase
120 Volts
2 Kilowatt
Anti-Friction Bearings
Provides power to heating element
Parameters Monitored
Misalignment Conditions
Besides the aligned condition, the machine was increasingly misaligned in the vertical and horizontal
directions. The pure offset misalignments were typically 10, 25, and 50 mils, and pure angle
misalignments were typically 1,5, and 15 mils/inch (17.45 mils/inch = 1°)
Vibration & Motor Current

Vibration spectra and time waveforms were gathered using normal averaging and high resolution time
synchronous averaging. Time synchronous averaging was utilized because the high level of electrical
signals generated by the single-phase motor.
Motor current was gathered in different frequency spans and resolutions to monitor the line and rotor bar
frequencies.
Phases
Phase at 1x, 2x, and 3x RPM were monitored in the radial and axial directions. The outboard axial
readings were taken around the clock face, at 12, 3, 6, and 9 o'clock Inboard axial readings were also
taken. If phases did not stabilize after one minute, phase at that point and speed was labeled "unstable".
Temperature
Temperature was measured at the end of each misalignment route, which took about 2% hours to
complete. Temperature was measured with an infrared temperature probe at all bearings and at the
coupling hubs.
Amplitude & Spectral Results
General
The amplitude data was analyzed to locate those multiples of running speed that provided the highest
levels and those that trended upward as the misalignment increased. Harmonics up to 8x were reviewed,
but only up to 6x was included in the analysis since amplitudes at 7x and 8x were so small. The
amplitudes were sorted into blocks by increasing amounts of offset and angular misalignment. If the
amplitudes in each block trended upward it was flagged as good indicator. The number of good blocks and
the highest amplitudes determined which harmonic of running speed was the best indicator for each
coupling. Table 3 shows the results for each coupling. The Grid coupling had the best misalignment
response with 63% of the amplitude blocks trending upward. The Shim coupling was the worst with
12.5%.
Rotor bar frequencies (24x and 28x) were also reviewed. They did not show an upward trend as the
misalignment increased in any direction. Outboard measurement points trended misalignment as often as
inboard measurement points, however the highest amplitudes were found at the inboard bearings.
Also, no correlation was found with respect to:
a Angular misalignment more prone to revealed itself in the axial direction and offset misalignment
in radial direction.
b. Vertical misalignment affects the horizontal measurement points and visa versa.
Bun Coupling
The spectra shown are from point Generator Inboard Horizontal (GIH) as the horizontal offset
misalignment increased from the aligned condition to 75 mils. This point provided the most reliable
spectral data and also provided the best upward trend. The spectral content shown in Figure 5 is typical of
this coupling. As shown in the data, 2x times running speed proved to be the most consistent misalignment
indicator for this coupling. The highest amplitudes (0.292 ips-pk) were generated at GIH as the machine
was offset in the vertical direction 75 mils (12.5 mils above tolerance).
Based upon the data the following was concluded for this coupling:
1. 2x RPM was the best amplitude to track to find misalignment as a whole.

2. Horizontal misalignment was difficult to find.
3. 1x RPM was not much help.
Jaw Coupling
The spectra shown in Figure 6 are from measurement points Generator Inboard Axial (GIA) as the
horizontal angular misalignment increased. The offset misalignment was increased to 25 mils (10 mils
above tolerance) and the angular was increased to 15 mils/inch (0.86°). These spectra show the typical
high harmonic content that was generated while the jaw coupling was in service. Amplitudes at 2)( RPM
were much lower, but the overall energy generated was high. 3x and 5x prove to be the best harmonics to
track a misaligned condition. Amplitudes at 3x reached 0.09 ips, pk at GIA and GIH, caused by both
angular and offset misalignment Amplitudes at 5x reached 0.12 and 0.15 ips, pk at GIV and GIH, caused
by both angular and offset misalignment.
1. 3x RPM was the best amplitude to track to find misalignment as a whole.

2. 5x RPM was a good indicator in this case because of the frequency response function (FRF).
3. Horizontal and vertical misalignment was just as easy to find when 3x is tracked.
Shim Coupling
The spectra shown in Figure 7 are from the measurement point Motor Outboard Vertical (MOV) as the
horizontal angular misalignment increased. The offset misalignment was increased to 50 mils and the
angular was increased to 15 mils/inch (0.86°). This was the quietest and smoothest running coupling
tested. All amplitudes were low. The highest amplitude was 0.0654 ips-pk at 2x on measurement point
GIH in the aligned condition. Typically the amplitudes were highest at 2x running speed, but were
typically down around 0.01 ips-pk. Consistent upward trends were difficult to find, with 6x the best
indicator. Amplitude trends typically decreased as the misalignment increased and started to increase at
the maximum misalignment.
1. 6x RPM was the best amplitude to track to find misalignment as a whole However its track record
was not good, correct only 30% of time. 2x RPM had the highest amplitudes, but did not typically
(only 10%) trend upward.
2. Any misalignment was difficult to find. Therefore, caution should be used when using this
coupling. The vibration maybe low, however stresses are still working on the critical components.
Another machine with this type of coupling was tested at a customer's facility. The machine was a 700 Hp
induction motor driving a multi-stage pump. The response was measured from several misaligned
conditions. The amplitude and spectral response generated similar information. No amplitudes trended
upward as the misalignment increased. A typical set of spectra are shown in Figure 8.
Grid Coupling
The spectra shown in Figure 9 are from measurement points Generator Inboard Vertical (GIV) as the
horizontal offset misalignment increased. The offset misalignment was increased to 50 mils and the
angular was increased to 15 mils/Inch (0.86°). These spectra show that the 4x RPM peak is a good
indicator of the amount of misalignment, with the maximum amplitude of 0.2056 ips-pk showing up at
GIV with 50 mils of offset in the horizontal direction. Not only did the 4x harmonic peak generate the
highest amplitudes, but also showed an upward trend as the misalignment increased 80% of the time.
Accuracy (trended upward) of the 1x and 2x RPM peaks were 35% and 60%, respectively.
1. 4x RPM was the best amplitude to track to find misalignment as a whole. Also producing the
highest amplitudes.
2. Misalignment was not difficult to find.
Rubber Internal Gear Coupling

This was also a quiet and smooth operating coupling. Again, all amplitudes were low. The highest
amplitude was 0.0204 ips-pk at 2)( RPM at measurement point GIH which was misaligned by 15
mils/inch in the horizontal direction. Typically the amplitudes were highest at 2)( running speed, but were
typically down around 0.01 ips-pk. As shown in Figure 10, consistent upward trends were difficult to find,
with 6)( being the best indicator. Amplitude trends typically increased as the misalignment increased but
upward trends ware minimal, typically starting at 0.004 ips-pk and increasing to 0.010 ips-pk.
1. 6x RPM was the best amplitude to track to find misalignment as a whole. However its track
record was not excellent, correct 53% of time. 2x RPM had the highest amplitudes and trended
upward 43% of the time.
2. Any misalignment was difficult to find since the synchronous amplitudes ware so low. Therefore,
caution should be used when using this coupling. The vibration maybe low, however stresses are
still working on the critical components.
Another machine with this type of coupling was tested at a customer's facility. The machine was a 100 Hp
induction motor driving a single stage centrifugal water pump. We measured the response from several
misaligned conditions. The amplitude and spectral response generated similar information. This being
small upward trends with increased misalignment and 2x being the best indicator. A typical set of spectra
are shown in Figure 11.
Phase Results
It was difficult to decide how to reduce all the phase data down into something practical, Phase
differences were calculated across the coupling for the axial and radial measurement points, Phase
differences were also calculated from end-to-end of the motor and the generator. These differences sorted
by the type of coupling, type of misalignment, and misalignment direction. Each group was considered a
phase block. A phase shift was flagged if it was a multiple of 180°, ±15° Unstable phases were not
considered in phase shift calculations.
Total phase accuracy was calculated by taking all 180° phase shifts and dividing by the total number of
times a phase shifts could have occurred. The phase block accuracy was determined by dividing the
number of phase blocks that shifted by the total number of applicable phase blocks.
If just the raw percentages are reviewed (see Table 4), phase analysis does not appear to be a good
indicator of misalignment. The numbers typically ran in the low to mid 20% range. Phase indicated
misalignment the best on the Jaw Coupling and the worst on the Rubber Gear Coupling.
However, the percent accuracy is not how the phase is typically used in the field. It is utilized by
determining the number of 180' phase shifts measured during operation. The greater the number of 180'
phase shifts the more likely that a misaligned condition does exist. The results of this are shown in the
final column of Table 4. The number of phase shifts increased in some of the couplings as the
misalignment increased to a certain point. A YES is logged in the above table for those that did. It is
interesting to note that for the maximum misalignments (50 mils offset and 15 mils/inch angle) the
number of phase shifts per condition decreased. Also there appears to be a relationship between the
accuracy percentages and the phase shifts, with the cut off point being around 15%
Tests on the 100 Hp and 700 Hp machines produced similar results. The results from the 700 Hp machine
(which used a shim type coupling) were: Total Accuracy = 20%, Block Accuracy = 40%, and the number
of phase shifts did increase with the amount of misalignment. The 100 Hp machine (which used a shim
type coupling) results were: Total Accuracy = 7%, Block Accuracy = 0%, and the number of phase shifts
did not increase with the amount of misalignment.
Motor Current Results
We believe that the motor current portion of the experiment actually raised more questions than it
answered. It was expected that by measuring the motor current it could be determined that proper
alignment can save money by reducing the amount of wasted energy consumed to overcome forces
induced by misalignment. This held true for the Bun coupling. With higher degrees of misalignment, the
motor current increased small amounts, ranging from 2.1% to 4.9%. The savings typically did not increase
as the misalignment increased This raises a question, Are the saving percentages the same for larger
machines if they are properly aligned?
Jaw coupling motor current results did differ from the bun coupling. All motor currents at line frequency
decreased as the misalignment increased, opposite of what was expected. This was true regardless of the
type or direction of misalignment. However, "two times slip" sidebands around line frequency and all
harmonics of line frequency increased in amplitude. The increase in amplitudes occurred during the initial
misalignment and remained at that those levels. They did not increase as the misalignment Increased.
The remaining couplings produced wild results. The motor currents varied up and down as the
misalignment increased. Further investigation revealed that the electrical system under test did not have a
stiff voltage. When the system was loaded, the voltage was pulled down significantly. In order to
compensate for this, voltage and input power factor should have been measured, but was not. Also, the
'"two times slip" sidebands did not react as they did with the Jaw coupling. All delta amplitudes (between
the line amplitude and the lower sideband amplitude) remained stable as the misalignment increased. The
Shim Coupling remained around 49 dB, the Grid Coupling around 47 dB, and the Rubber Gear around 51
dB.
Temperature Results
As with the other measured parameters (vibration, motor current, and phase) the temperature response to
misalignment varied with the type of coupling. Some indicated misalignment well, especially when
looking at the coupling temperature. Table 5 below shows how the couplings ranked using temperature as
a misalignment indicator. The All Points Block Accuracy is the number of temperature blocks that showed
an upward trend divided by the total number of chances. This includes the temperatures at the motor
bearings, generator bearings and the coupling hubs. Considering all couplings, the coupling measurement
point showed the most consistency, therefore the Coupling Temperature Block Accuracy column shows
how often this particular location showed an upward trend. The table shows that the Grid coupling was the
best of the couplings tested and the shim coupling was the worst.
Results from the larger machines (700 Hp and 100 Hp) showed similar results. Coupling block results on
the shim coupling (700 Hp) and the rubber gear coupling (100 Hp) were 0% These two couplings also
performed poorly as an indicator in the above data.
Conclusions
Amplitude and Spectral

Probably the most significant item learned from this experiment is that the spectral information generated
by a machine is very dependent upon the type of coupling. Figure 12 shows a set of spectra from the same
measurement point (GIH) with similar misaligned conditions. Troubleshooting personnel should take this
into consideration while doing their job. Also beware of the type of coupling being used prior to
performing running alignments or running soft foot checks. CSI does not condone these type of checks.
Phase Analysis
When looking at the number of phase shifts over the complete machine, phase analysis is a good indicator
for several couplings and not for others. So, before performing this type of analysis know what type of
flexible coupling is used on the machine being tested. See Table 4 for results on each coupling.
Motor Current
Hopefully you can learn from our mistakes. Much care has to be taken when determining the effects of
misalignment on the efficiency of the total machine. Just measuring motor current is not enough. To
determine the effects the machine, it should be operated at the same load before and after alignment. For
example, a motor-pump combination should be operated at the same flow rate before and after. Also, if
the machine is not on a stiff (with respect to voltage) system, measure voltage and input power factor. The
proper amount of savings can be calculated from this information.
Temperature
If using temperature as a misalignment indicator you should be aware of what type of coupling is installed
on the machine, see Table 5 to see those couplings tested. Also, the best measurement point location is the
coupling itself, preferably one of the coupling hubs. Be sure to use a non-contact method, such as infrared,
to measure since the coupling is rotating.
Some of the upward trends found were small. The increase is small enough that a variation in ambient
temperature or the process could affect the temperature more than the misaligned condition. These
parameters were held constant during the test, but the process may have affected the results from the large
machines.
General
It is evident from the data that the troubleshooter in the field should always be aware of the type of
flexible coupling being used before any final decisions are made. Different couplings affect the spectral
shape (Figure 12), phase (Table 4), motor current, and temperature (Table 5)
During the test, responses were measured within three operating hours of the initial startup for each
condition. Misalignment maybe like heart disease, it maybe required to operate in a poor condition awhile
before symptoms start showing up. In the case of misalignment, time to allow the misalignment stresses to
open up clearances
Most of the results generated from this experiment were from a machine smaller than the typical machine
in the field Further testing should be performed on larger machines using the same type couplings. Some
tests have been performed with the shim and rubber gear designs, which confirmed most of the results
obtained from the small machine.
All contents copyright © 1998 - 2006, Computational Systems, Inc.

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Emerson Process Management - CSI Page 1 of 15

DoctorKnow® Application Paper

CHARACTERIZING SHAFT MISALIGNMENT EFFECTS

By Dan Nower, P.E. & Curt Thomas

Most of us are familiar with the traditional vibration analysis rules:

1. 2x running speed amplitude

-Radial direction for offset misalignment

2. 0° and 180° Phase Shifts

Radial direction for offset misalignment

Test Machine & Couplings

Vibration & Motor Current

Amplitude & Spectral Results

Also, no correlation was found with respect to:

1. 2x RPM was the best amplitude to track to find misalignment as a whole.

1. 3x RPM was the best amplitude to track to find misalignment as a whole.

Rubber Internal Gear Coupling

Motor Current Results

Amplitude and Spectral

All contents copyright © 1998 - 2006, Computational Systems, Inc.

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