Benefits Shaft Alignment

BENEFITSAlignment Shaft
THE
IMPORTANCE OF SHAFT ALIGNMENT
Misaligned rotating machinery has caused, and will continue to cause, a tremendous financial loss to every industry worldwide. John Pietrovski Author of Shaft Alginment Handbook
Aligning your shafts mean...
... increased operating time ... increased productivity ... increased production quality
Misaligned shafts...
... is a risk to your business ... lead to unplanned production stops ... consume more power ... can affect the quality of the product you are manufacturing
Alignment of machines has been performed for over 200 years. The reasons have not always been obvious, but in the modern world the necessity of alignment is a common knowledge. With todays optimized machinery, alignment is a vital part in the daily maintenance work. Machines need to be on-line continuously with a minimum of interruptions. A machine breakdown causes devastating loss of production. Nearly 50% of all machine breakdowns are caused by misalignment. Shaft Alignment can be performed with lot of different tools. The easiest way is to use a ruler or a straight edge over the two coupling halves and align by eyesight. The result is not very accurate and it is very operator dependent. To achieve a far better result is to use mechanical dial indicators. A skilled and experienced user can achieve good and reliable result, but it takes time. The far easiest way, and most accurate, is to use laser based alignment systems. They do not require special skill and delivers very accurate and repetitive results.
DEFINITION OF MISALIGNMENT
Misalignment is the deviation of relative shaft position from collinear axis of rotation when equipment is running at normal operating conditions.
HOW IS MISALIGNMENT RECOGNIZED?

There are several symptoms indicating misalignment. By keeping your eyes open you can find them without any special equipment. Premature bearing, seal, shaft and coupling failure Excessive radial and axial vibrations High casing temperature at or near the bearings or high discharge oil temperature Excessive amount of oil leakage at the bearing seals The coupling is hot while it is running and immediately after unit shutdown. Look for rubber powder inside the coupling shroud Loose foundation bolts Loose or broken coupling bolts Excessive amount of grease on the inside of coupling guard Similar pieces of equipment are vibrating less or seem to have longer operating life The shafts are breaking (or cracking) at or close to the inboard bearings or coupling hubs
Parallel offset.
Angular error.
EFFECTS OF BASE CONDITIONS AND THERMAL VARIATIONS

Even if you align your machines properly there is a risk that they brake due to misalignment. If the foundation where the machine is mounted is warped you may have a soft foot condition, i.e. one of the machine feet has a poor contact with the floor. It is of major importance that this is corrected before performing the alignment. If the alignment is performed when the machines are cold, and no compensation for thermal growth is considered, the machines will probably be running severely misaligned at running temperature.
Misaligned machines is the direct cause to nearly 50% of all rotating machine breakdowns.
ALIGNMENT TOLERANCES
Most manufacturers of machines specify the amount of misalignment accepted by their machine. Use the tables below as a guide if no other specifications are available. Note that the figures in the table are the most common used tolerance on standard machinery. Tolerances of 0, 03 mm/m can not be achieved to without using special tools. High speed machinery and turbines require alignment within thousands of a millimeter per meter.
Differences in temperature can cause severe misalignment due to the fact that machine casings and pipes expand with raised temperature.
MISALIGNMENT AND POWER CONSUMPTION

Misalignment has a direct impact on the power consumption. Documented cases have shown savings ranging from 2 to 17%. The thermogram below shows to different couplings and the amount of heat generated due to misalignment.
Where P=Fr+Fa=Bearing load C=Constant depending on bearing type L 10=Lifetime in million turns
MISALIGNMENT EFFECTS ON BEARINGS

AND SEALS
The bearings operating life span is directly affected by the forces it is exposed to. The slightest misalignment can generate excessive forces to the bearings and seals. A misaligned machine causes stress to both bearings and shafts. As an effect of this the seals opens up, allowing lubrication leakage and contamination to enter. All together the bearings lifetime is dramatically shortened.
Doubling the force reduces the lifetime to 1/8th, three times the force reduce lifetime to 1/27th of the original lifetime.
Aligned - the seal is keeping the bearing lubricated and clean.
Centerline of motor bearings.
Centerline of pump bearings. Mechanical seals or packing.
Misaligned - note the open seal.
Photography by Infraspection Institute
L10 = C P
()
FREQUENTLY ASKED QUESTIONS

WHERE
CAN
EXPECT TO FIND ALIGNMENT PROBLEMS?
Wherever you have rotating shafts there is a need for alignment. The higher speed the more accurate alignment is required. If an application is generating vibrations, you should always check the alignment.
DOES
MISALIGNED MACHINES CONSUME MORE POWER ?
Misaligned machines generate forces to the bearings and the coupling. This force is converted to heat and can easily be recognized using a thermo sensitive camera.
DO I
NEED TO ALIGN WHEN
USE FLEXIBLE COUPLINGS?
Flexible couplings are necessary. They reduces the detrimental forces, due to misalignment, during the start up until the machines have reached the operating temperature. A flexible coupling can only absorb a very small amount of misalignment. Even then the components is exposed to stress and wear quicker. It is therefore important to align the machines for running conditions and not cold conditions.
HAVE NEW MACHINES, DO
REALLY NEED TO CARE ABOUT ALIGNMENT ?
A machine, such as motor and pump, is often delivered on a frame or baseplate. Plug and play, sort of. Even if the machine is perfectly aligned from the supplier it does not mean it is perfectly aligned when bolted down and connected to the pipes in your factory. Always check the alignment before starting the new machine.
WAS BEFORE WITHOUT DOING AN ALIGNMENT CHECK ?
WHY
CANT
REFIT THE OVERHAULED MACHINE IN THE SAME POSITION AS IT
Even if you mark up the position before you remove the machine you can not know if it will be positioned correctly. The alignment requirements for a standard motor/pump installation is 0, 03 mm/m or better. It is impossible to replace a machine within that tolerance whithout performing an alignment.
Publ.no:P-0063-GB
FIXTURLASER AB Box 7 SE-431 21 Molndal Sweden Phone: +46 31 706 28 00 Fax: +46 31 706 28 50 E-mail: info@fixturlaser.se Website: www.fixturlaser.se

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BENEFITSAlignment Shaft

Aligning your shafts mean...

HOW IS MISALIGNMENT RECOGNIZED?

EFFECTS OF BASE CONDITIONS AND THERMAL VARIATIONS

MISALIGNMENT AND POWER CONSUMPTION

MISALIGNMENT EFFECTS ON BEARINGS

Aligned - the seal is keeping the bearing lubricated and clean.

Centerline of motor bearings.

Centerline of pump bearings. Mechanical seals or packing.

Misaligned - note the open seal.

Photography by Infraspection Institute

FREQUENTLY ASKED QUESTIONS

EXPECT TO FIND ALIGNMENT PROBLEMS?

MISALIGNED MACHINES CONSUME MORE POWER ?

NEED TO ALIGN WHEN

USE FLEXIBLE COUPLINGS?

HAVE NEW MACHINES, DO

REALLY NEED TO CARE ABOUT ALIGNMENT ?

WAS BEFORE WITHOUT DOING AN ALIGNMENT CHECK ?

REFIT THE OVERHAULED MACHINE IN THE SAME POSITION AS IT

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