alignment module

Alignment Course Manual

IHRDC

GRADUATE ENGINEERDEVELOPMENT PROGRAMME

MECHANICAL DISCIPLINE

ALIGNMENT

IHRDC AL – M -02 (Rev – 0) 02 – 2 – 1999 Page- 1


Total Pages: (63)

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


Alignment

Graduate Development Programme Module (M – 02 )5D

This Module is designed for AFPC existing Mechanical Graduates, provide hands-on experience to perform both methods of shaft alignment using dial indicators.

This Module focuses on the preparations required prior to alignment job, the procedure to perform both methods and corrections for thermal growth.

Preparation for alignment. Face and rim alignment using graph. Reverse alignment using graph. Performing alignment using formulas. Correction for thermal growth.

Audience :Prerequisites :Location :Format :

Mechanical Graduates. English comprehension and communication.AFPC Training Center, D. Z.Lecture, discussion and OJT workshop practices.

This module is one of thirteen modules, which together cover the theoretical aspect of the Technical Training for the AFPC Mechanical Graduates Development Programme. This programme has been developed specifically for AFPC Graduate Development to enhance the dynamic Nationalisation drive adopted by the company.

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Course Contents

Page

1- Objectives. 4

2- Course Outline. 5

3- Equipment/ Resources. 7

4- Course Manual (Hands Out for Participants). 8

5- Training Aids. 44

6- Lesson Plan. 45

7- Course Final Assessment. 60

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1- Course Objectives:

Upon completion of this course, the employee should be able to :-

Lesson One: Preparation for Alignment:

Understand the orientation upon performing alignment. Demonstrate pipe strain correction. Perform soft foot. Explain run out readings. Understand thermal growth methods. Explain how to set the face gap. Demonstrate mechanical center. Demonstrate magnetic center. Perform bar sag.

Lesson Two:- Rim and Face Alignment (Vertical Plane)

Understand the measurement procedures. Understand the graphing procedure for alignment. Understand formula to correct misalignment. Understand graphing thermal growth to correct misalignment. Understand formula for thermal growth. Explain graphing procedure (Horizontal Pane). Explain how to carry out alignment using the formula.

Lesson Three:- Reverse Alignment Method (Vertical Plane)

Understand measurement procedures. Understand graphing procedures for alignment. Explain how to use the formula for alignment. Explain how to correct misalignment due to thermal growth. Explain graphing procedure for horizontal alignment. Explain formula method for horizontal alignment.

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2- Course Out Line:-

- This course is designed for AFPC existing Mechanical Technicians to provide hands on experience in alignment.

- Duration of this course is five working day’s (30 Hrs).- The course is to be conducted at AFPC Training center classroom and Mechanical

assembly workshop.- Course time plan shall be as follows:-

- Instruction Time 8 Hrs.- Workshop Time 16 Hrs.- Final Test Time 6 Hrs.

Course program shall be conducted as follows:-

Day – 1 (6.0 Hrs)

Time Hrs Activities Location

2

Lesson 1- Preparation for Alignment 1.1 Definitions.1.1.1 Alignment orientation.1.2 Equipment Preparations1.2.1 Pipe Strain.1.2.2 Soft Foot.1.2.3 Run Out Reading.1.2.4 Thermal Growth.1.2.5 Face gap.1.2.6 Magnetic Center.1.2.7 Mechanical Center

Classroom

3.30 Same Topics W/ S0.30 Assessment W/ S

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Day – 2 (6 Hrs)


1.30

Lesson 2:- Rim and Face AlignmentA. Vertical Plane2.1 Measuring Procedure.2.2 Graphing Vertical Plane Misalignment.2.2.1 Graphing Procedure.2.3 Using formula.2.4 Graphing Thermal Growth.2.4.1 Graphing Procedure.2.4.2 Graphing and Correcting Vertical Plane Misalignment.2.4.3 Calculation Using Formula.

Classroom

4 B. Performing Rim and face Alignment W/ S0.30 C. Assessment W/ S

Day – 3 (6 Hrs)


2

Lesson 2 Rime and face AlignmentHorizontal Plane

2.5 Graphing.2.5.1 Graphing procedure.2.5.2 Calculations using Formula.

W/ S

0.30 Assessment W/ S

2

Lesson 3 Reverse Alignment3.1 Vertical Alignment.3.1.1 Introduction.3.1.2 Measurements.3.1.3 Dial Indicator Readings.3.1.4 Graphing procedure.3.1.5 Cold Alignment Graph.3.1.6 Formula Method.3.1.7 Graphing Thermal Growth.3.1.8 thermal Growth Calculation.

Classroom

1 Performing Reverse Alignment W/ S0.30 Assessment W/ S

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Day – 4 (6 Hrs)


0.30

Lesson 3 Reverse Alignment3.2 Horizontal Plane.3.2.1 Graphing procedure.3.2.2 Correcting Misalignment using Graph.3.2.3 Formula method.

Classroom

5 Performing Reverse Alignment W/ S0.30 Assessment W/ S

Day – 5 (6 Hrs)

Time Hrs Activities Location1 Final Assessment Classroom5 Final Assessment (Practical) W/ S

3- Equipment and Resource

1- A motor and pump on a skid at W/ S.

2- Two clamps.

3- Two dial indicators.

4- Shims.

5- Video and Monitor.

6- Projector.

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4- Course Manual

(Hand out For Participants)

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SHAFT ALIGNMENT

1-Preparations for Alignment

1.1 Definitions:

Alignment: The relationship between the position of one shaft with another.

Shaft alignment: The proper positioning of equipment shafts so that the centrelines of the two shafts are colinear.

Parallel misalignment: A misalignment situation in which the centrelines of two shafts are offset so that they are not colinear, although they are parallel.

Angular misalignment: A misalignment situation in which the centrelines of two shafts intersect each other at an angle.

Colinear alignment: Alignment in which the centrelines of shafts are in the same line.

Combined misalignment: A combination of parallel and angular misalignment in both the horizontal and vertical planes.

1.1.1 Alignment Orientation

The person performing a shaft alignment should orient himself properly in relation to the equipment. The fixed component should be on the left, and the movable component should be on the right.There is another part of the orientation that must be considered. This can be explained by looking at the hub of the fixed component. The hub of the fixed component can be thought of as the face of a clock. The vertical plane is represented by 12 o’clock and 6 o'clock, which are above and below the shaft. The horizontal plane is represented by 9 o'clock and 3 o'clock, which are to the left and right of the shaft.

1.2 Equipment Preparation

One of the first shaft alignment preparations is making sure that the pump and motor are isolated and tagged out. If equipment is accidentally started up while an alignment is being performed, serious injuries can occur.

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Alignment Orientation

Hub of the fixed component as a clock face

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Another important preparation is inspecting the foundation, or bedplate, that supports the pump and the motor. The foundation should be checked with a bubble level to ensure that it is level.

1.2.1 Pipe Strain

Another part of preparing for an alignment is checking the fixed component for pipe strain. Pipe strain is the force exerted on the fixed component from suction and discharge piping that is not supported properly. If pipe strain is not corrected, it may be difficult to align the shafts properly.

One method of measuring pipe strain involves mounting two dial indicators on the foundation so that their stems contact the rim of the pump's hub. One of the dial indicators is mounted at 12 o'clock, and the other is mounted at either 3 o'clock or 9 o'clock. Attaching the dial indicators in this manner allows pipe strain to be measured in both the vertical and horizontal planes. After each dial indicator is securely mounted, both are adjusted for a zero reading. Then the bolts for the suction and discharge pipe flanges are loosened, and the flanges are separated. This will relieve any pipe strain that may have been present. The dial indicators are then checked. Any reading, other than zero on either dial indicator means that the pump moved because of pipe strain.

A facility usually has set limits for the amount of pipe strain that is allowable. In some facilities, any difference in dial indicator readings of more than 2 mils must be corrected.

To correct pipe strain, adjustments must be made in the piping supports. These adjustments may require that pipe hangers and supports be moved according to plant procedures. After the adjustments have been made, the procedure list described should be repeated to make sure that the pipe strain had been corrected.

1.2.2 Soft Foot Conditions

Another preparation that should be made before performing - an alignment is checking for a "soft foot" condition. A soft foot condition exists when one or more of the movable component's feet are in different planes. When this condition is present, the motor housing twists when the support bolts are torqued down. This twisting can make it difficult to properly align the shafts.The first step in checking for a soft foot condition is to tighten down all of the support bolts on the movable component. Then, a dial indicator is mounted to indicate vertical movement of one of the feet. The dial indicator is adjusted to a zero reading.

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Next, the support bolt on the foot is loosened, and the dial indicator reading is recorded. Any reading other than zero indicates a soft foot. Facilities generally have set limits for the amount of movement that allowable. In many facilities, any soft foot condition of more than 2 mils must be corrected.

To correct the soft foot, a shim that is the same size as the dial indicator reading must be inserted under the soft foot. The support bolt is then retightened.

The steps just described must be repeated for each of the remaining, feet. The number of soft feet can vary. In some cases, it may only be necessary to shim one foot. In other cases, two or three feet may have to be shimmed. After each foot has been checked and shimmed, if necessary, each foot should be rechecked to verify that the soft foot condition has been corrected.

1.2.3Taking Runout Readings

Another preparation that should be made is taking runout readings on both the fixed component and movable component. Runout readings measure how much the hub or shaft is out of round. Excessive runout can make it difficult to properly align shafts.

To obtain runout readings, a dial indicator is mounted so that its stem contacts the rim of the hub.

After the dial indicator is adjusted for a zero reading, the shaft is rotated slowly while the dial indicator is observed. Any movement of the dial indicator needle indicates runout.

Facilities generally specify the amount of runout that is allowable. Reading in excess of the allowable limit indicate a bent shaft or a misbored hub. Which component is at fault can be determined by taking another set of runout readings with the dial indicator stem contacting the shaft. Excessive runout under these conditions indicates a bent shaft, which will require replacement of the shaft. Readings within tolerance on the shaft indicate a misbored hub, which requires the hub to be replaced.

1.2.4 Measuring Thermal Growth: Method 1

One method of measuring thermal growth involves mounting dial indicators so that their stems are in contact with the two shafts while the components are at operating temperature, and then waiting for the components to reach ambient (room) temperature. The dial indicator readings at ambient temperature indicate how much movement has occurred.

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Dial indicators are mounted so that their stems contact the shaft of each component at 6 o'clock, so they will measure vertical movement. Both dial indicators are zeroed while the equipment is still at operating temperature. It is necessary to mount the base used for each dial to the foundation or some other place that will not be affected by thermal growth.

1.2.5 Measuring Thermal Growth: Method 2

This method involves using a Pyrometer to measure the ambient and operating temperatures of the components. These temperature values are then factored into a formula that uses the thermal expansion coefficient of steel to determine the amount of thermal growth. This method uses a Pyrometer to measure both the ambient temperature and the operating temperature of the component.

The ambient temperature is recorded. The distance between the base plate and the centreline of the component's shaft is also measured and recorded.

Next, the component is started up and allowed to reach normal operating temperature. Then the temperature is again measured.

Next, the ambient temperature is subtracted from the average operating temperature at the inboard feet. The result of this subtraction is then multiplied by the distance between the base plate and the centreline of the shaft.

Next, the product of this multiplication is multiplied by the therma1 expansion coefficient for iron and steel, which has a value of .0000063. The final result indicates the actual amount of movement that will occur due to thermal growth

1.2.6 Setting the Face Gap

Most couplings are designed to operate with a specified amount of space between the hubs. This space, called the face gap prevents damage to the hubs and the coupling from axial movement of the shafts. Axial movement refers to the amount of movement, back and forth along the axis of a shaft, that is allowed by the bearings that support the shaft. If the face gap is too narrow, axial movement may cause the two hubs to contact each other and become damaged. If the face gap is too wide, the coupling may separate and be damaged.In order to set the face gap, the motor must be moved into position. A feeler gauge the size of the ideal face gap specification is then inserted between the hubs.The feeler gauge should just fit between the two hubs. Many mechanics use a straightedge and a feeler gauge to get the two shafts close to proper alignment.

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The face gap should be rechecked after any motor movement. When the face gap is set, the motor support bolts should be tightened.

Setting the face gap for a pump and motor that use anti-friction (ball or roller) bearings can be accomplished with this procedure. However, when large components are involved, particularly components that have sliding surface bearings, some additional steps are required.

1.3 Determining Mechanical Centre

In equipment that uses anti-friction bearings, the amount of axial movement may be insignificant, on the order of 2 mils or less. However, when sliding surface bearings are used in rotating equipment, the amount of axial movement may be significantly higher. In these situations, it is necessary to determine the mechanical centre of the component before adjusting the face gap.

The mechanical centre can be defined as the normal operating position of a shaft. Usually, it is equal to one half of the total axial shaft movement. The mechanical centre can be determined by measuring the total amount of axial movement with a dial indicator and then dividing that value by 2.

To determine the mechanical centre of a piece of equipment, the shaft of the equipment is forced inward as far as it will go. Then, a dial indicator is mounted so that its stem contacts the face of the hub. The dial indicator is then adjusted for a zero reading.

The shaft is then forced outward as far as it will go. The reading on the dial indicator at this point is the total amount of axial shaft movement.

To determine the mechanical centre, the total amount of axial shaft movement is divided by 2. The shaft is then moved back inward until the dial indicator reads half of the total movement. At this point, the shaft is set to its mechanical centre.

1.4 Determining Magnetic Centre

Axial movement is present in motors, as in other types of rotating equipment. However, because of the magnetic field that is created by a motor's field windings, the rotor is held in the same position each time the motor operates. This position is referred to as the motor's magnetic centre. With some motors, the magnetic centre must be determined before the coupling face gap is adjusted.After the motor is started, the shaft should be sprayed with layout dye. A mark willbe made in the dye to indicate the motor's magnetic centre.

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When the motor reaches normal operating speed, a line is lightly scratched into the dye on the shaft using the end bell or similar part of the motor as a reference point. The motor is then shut off. The mark on the shaft when lined up with the reference point indicates that the shaft is at magnetic centre.

After the fixed component has been set to the mechanical centre and the motor has been set to the magnetic centre, the face gap can be set to the ideal specification. Setting the face gap to the ideal specification should allow axial movement to occur without damaging the hubs or the coupling.

1.5 Measuring Bar sag

Summary ChecklistThe following are the major steps involved in measuring bar sag.

(1) Measure the height and distance between the brackets.(2) Mark the shafts along at least one edge of each bracket so that the

brackets can be reinstalled in the same place after the amount of bar sag has been determined.

(3) Mount the dial indicators and brackets on a test fixture.(4) With the dial indicators at the 12 o'clock position, adjust the "P" dial

indicator to a zero reading,

(5) Rotate the test fixture to the 6 o'clock position. (6) Take a reading on the "P" dial indicator. (7) Divide the reading by 2 and record the value on a data sheet.(8) Reinstall the brackets and the dial indicators on the shafts of the

equipment to be aligned.

Bar Sag Causing Negative and Positive Readings

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2. Rim and Face Alignment

(A) Vertical Plane

2.1 Measurement Procedures

The following, are the major steps that should be followed when using the rim and face method to measure misalignment in the vertical plane.

(1) Determine the swing diameter. Measure the distance between the centerline of the shaft and the centerline of the "A" dial indicator's stem. Multiply the measurement by 2, and record this value on thedata sheet in the area labeled “D”.

(2) Measure the horizontal distance from the target of the “A” dial indicator to the centerline of the support bolt for the motor foot that is nearest to the hub. Record the value of this measurement on the data sheet in the area labeled “X”.

(3) Measure the horizontal distance from the target of the “A” dial indicator to the centerline of the support bolt for the motor foot that is farthest from the hub. Record the value of this measurement on the data sheet in the area labeled "Y."

(4) Rotate both shafts so that the brackets are at the 12 o'clock position.

(5) Rotate the face of each dial indicator so that a reading of zero is obtained.

(6) Rotate both shafts one complete revolution to make sure that the brackets and the dial indicators are securely fastened.

(7) Observe the dial indicators while rotating both shafts to the 6 o'clock position.

(8) Record the "P” dial indicator reading on the data sheet.

(9) Record the "A" dial indicator reading on the data sheet.

(10) Check for accuracy by repeating the above steps. Compare the first set of readings with the second set, making sure that they match. If not, make the necessary adjustments and take the readings again.

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Tape Measurements

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Rim and Face AlignmentVertical Plane

2.2 Graphing Vertical Plane Misalignment

2.2.1 Graphing Procedure

The following are the steps involved in graphing and correcting, for misalignment in the vertical plane.

(1) Choose a point of reference, or base point, on the left side of the graph paper.

(2) Draw a line, called the base line, from the base point to the right side of the graph.

(3) Plot "D" from the data sheet by starting at the base point and moving along the base line the value of "D."

(4) Plot "X" from the data sheet by starting at point "D" and moving along the base 'line the value of “X".

(5) Plot "Y" from the data sheet by starting at point "D" and moving along the base line the value of "Y."

(6) Plot "AV" from the data sheet, starting at the base point and moving up if the value is positive or moving down if the value is negative.

(7) Draw a line, called a "reference line," from point "AV” throughPoint “D”

(8) Plot "XA” on the reference line by starting at point "X" on the base line and moving straight up or down to the reference line.

(9) Plot "YA” on the reference line by starting at point "Y" on the base line and moving straight up or down to the reference line.

(10) Plot the value of "PV" from the data sheet. Starting at point "XA”. Move up if the value is positive or down if the value is negative. Label the resulting point “XAP”

(11) Repeat Step 10, starting at point “YA” and label the resulting, point “YAP.”

(12) Draw a dashed line that intersects points "XAP” and "YAP." This line represents the combined angular and parallel misalignment in the vertical plane.

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Calculation for Parallel Misalignment Value for angular misalignment in in the vertical plane in the vertical plane

Graphing an correcting vertical plane misalignment

Increments between points “X” and “ XAP” and between points “Y” and “ YAP”

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2-3 Using Formulas

Thermal growth for motor and pump are equal (or no thermal growth).

Instead of graphs, formulas can be used to determine how much to move the motor to correct for both angular and parallel misalignment in the vertical plane. One formula is for the inboard feet and the other is for the outboard feet. The formula for the inboard feet is as follows:

XInboard = x AV - PV

DThis formula is used when the thermal growth values for the movable componentand the fixed component are equal. The values for this formula are obtained fromthe data sheet. With the values from the example in Figure F-1, the formula reads: 12

Inboard = x (+ 6) - (- 6.5) 10

Working through the math gives an answer of +13.7 mils, which can be rounded off to +14 mils. When formulas are used, a negative answer indicates that the motor feet must be moved down to bring the shafts into alignment. A positive answer indicates that the motor feet must be moved up to bring shafts into alignment. An answer of +14 mils indicates that the inboard feet should be moved up by adding 14 mils of shims.

The formula for the outboard feet is as follows: Y

Outboard = x A V- PV D

Again, this formula is used when the thermal growth values for the movable component and the fixed component are equal. The values for this formula are also obtained from the data sheet. With the values shown, the formula reads:

24Outboard = X (+6) -(- 6.5)

10Working through the math gives an answer of +20.9 mils, which can be rounded off to +21 mils. This means that the outboard feet must be moved up by adding 21 mils of shims.

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2.4 Graphing Thermal Growth

2.4.1 Graphing vertical plane misalignment (Continued item 2.2.1) Graphing Procedure.

(13) Move the base line and/or the dashed line to account for thermal growth indicated on the data sheet.

(14) Count the increments between points "X" and "XAP”' and between points "Y" and “YAP” to determine how much to adjust the inboard feet and the outboard feet.

(15) Move the motor up, by adding shims under the motor feet, if the dashed line is below the base line. Move the motor down, by removing shims from under the motor feet, if the dashed line is above the base line.

Increments between points “X” and “ XAP” and between points ‘Y” and “YAP”

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Data Sheets

Data Sheets showing different thermal growth characteristics

Graphing Thermal Groth

Graph modified for thermal growth

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2.4.2 Graphing and Correcting Vertical Plane Misalignment (Thermal Growth).When graphing thermal growth characteristic values, it is necessary to consider the signs of the values. As shown on the data sheet, the pump has a thermal growth value of -2 mils. This means that the pump shaft is actually 2 mils lower at operating temperature than it is at ambient temperature. This is typical for pumps that move cold liquids.Earlier, it was stated that the base line of the graph (the line containing points“X" and "Y") represents the position to which, the movable component must be moved in order to align the shafts. Since the movable component's shaft is to be aligned to the fixed component's shaft, the base line can also represent the fixed component's shaft. This representation can be used to graph the fixed component's thermal growth characteristics. Basically, it involves creating, a new base line that includes the thermal growth characteristics of the fixed component. If the fixed component has a positive thermal growth value, the new base line must be drawn above the existing base line. If the fixed component's thermal growth value is negative, the new base line is drawn below the existing base line. In the example, the fixed component has a thermal growth value of -2 mils. Therefore, the correct procedure is to move down 2 mils from the existing base line and draw a new base line that represents the fixed component's shaft at operating, temperature.

The shaft of a motor is generally higher at operating temperature than it is at ambient temperature, because motors generate heat, which causes their casings to expand slightly. In this example, the motor has a thermal growth value of +2 mils, so the motor shaft is 2 mils higher at operating temperature.

The thermal growth value for the movable component can be graphed in a manner similar to that described for the fixed component. However, the dashed line (the line containing points “XAP” and "YAP”) must be used instead of the base line, since the dashed line represents the movable component's shaft. A positive thermal growth value requires a new dashed line to be drawn above the existing one. A negative thermal growth value requires a new dashed line to be drawn below the existing one. Since this example involves a thermal growth value of +2 mils, a new dashed line must be drawn 2 increments above the existing one. This line, then, represents the angular and parallel misalignment with thermal growth factored in.After the base line and the dashed line have been replotted to account for thermal growth the increments are counted between points “X” and "XAP”, and points "Y" and "YAP," in their new positions. The number of increments represents the distance that the motor must be moved to correct for angular and parallel misalignment and thermal growth in the vertical plane. It is important to remember that when the motor is moved by the amount indicated on the graph, the shafts will be misaligned while the components are at ambient temperatures.However, the two shafts will be aligned at operating, temperatures.

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2.4.3 Calculations of vertical plane misalignment using the formula for the Combined thermal growthIf components have different thermal growth characteristics, the thermal growth values must be used to determine how much to move the motor to correct for misalignment in the vertical plane when the components have reached their operating temperatures. In order to account for the movement that takes place due to thermal growth, the thermal growth value for the movable component must be subtracted from the value for the fixed component. This operation can be expressed as the following formula:

Thermal Growth Thermal Growth Combined - = Fixed Movable Thermal GrowthAssuming that the pump has a thermal growth value of -2 mils and the motor has a value of +2 mils, the formula reads:

-2 mils - (+2 mils) = -4 mils

The combined thermal growth value is added to the formulas used to determine the amount of movement needed for the inboard and outboard feet to correct for vertical misalignment. The formula for the inboard feet is as follows:

X Combined ThermalInboard = ( x AV ) - PV +

D Growth

With the values determined previously, the formula reads: 12

Inboard = ( x (+ 6)) – (-6.5) + (-4) 10

Working through the math gives an answer of +9.7 mils, which can be rounded off to +10 mils. An answer of +10 mils indicates that the inboard feet should be moved up by adding 10 mils of shims. A negative answer indicates that the motor feet must be moved down.The formula for the outboard feet, when thermal growth is a factor, is as follows:

Y Combined ThermalOutboard = ( x AV) –PV ) + D Growth

With the values determined previously, the formula reads:

24Outboard = ( X (+ 6)) - (- 6.5) + (- 4)

10

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Working through the math gives an answer of +16.9 mils, which can be rounded off to + 17 mils. This means that the outboard feet must be moved up by adding 17 mils of shims.

It is important to remember that when thermal growth is factored into the formulas and the motor is moved by the amount indicated by the answers, the shafts will be misaligned while the components are at ambient temperatures. However, the twoshafts will be aligned at operating temperatures.

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2- Rim and Face Alignment

(B)Horizontal Plane

2.5 Graphing horizontal plane misalignment

2.5.1 Graphing procedure

The following are steps involved in measuring, graphing, and correcting for misalignment in the horizontal plane.

(1) Rotate both shafts so that the dial indicator brackets are at the 3 o'clock position.

(2) Rotate the face of each dial indicator so that a reading of zero is obtained.(3) Rotate both shafts one full revolution to make sure that the brackets

and dial indicators are securely fastened.(4) Observe the dial indicators as the shafts are rotated to the 9 o'clock

position. Take readings on both dial indicators and record the valueson the data sheet.

(5) Repeat the procedure to take another set of readings. Compare themwith the previous set to make sure that they are consistent.

(6) Perform the calculations required by the data sheet and enter values"PH” and "AH."

(7) To begin graphing horizontal misalignment, establish the base point.draw the base line, and plot the values of "D," "X," and "Y" from thedata sheet.

(8) Plot the value of "AH” on the graph by starting at the base point andmoving up if the value is positive and down if the value is negative.

(9) Establish the reference line by drawing a straight line from point"AH" through point "D."

(10) Plot point “XA” by starting at point "X" on the base line and moving up or down to the reference line.

(11) Plot point "YA” by starting at point "Y" on the base line and moving up or down to the reference line.

(12) Starting at point “XA," move the value of "PH," up if positive and down if negative. Label the resulting point "XAP."

(13) Starting at point “YA”, move the value of “PH, " up if positive and down if negative. Label the resulting point "YAP."

(14) Draw a dashed line that intersects points "XAP” and "YAP." This line represents the combined angular and parallel misalignment in the horizontal plane.

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(15) To determine how much the motor has to be moved in order to bring the shafts into horizontal alignment, count the increments between points "X" and "XAP” and between points "Y" and "YAP." The motor should be moved toward 3 o'clock if the dashed line is below the base line. The motor should be moved towards 9 o'clock if the dashed line is above the base line.

(16) Before actually moving the mtor to correct for horizontalmisalignment, mount a dial indicator on both an inboard foot and an outboard foot in order to determine when the proper amount of movement has been made. Set each dial indicator for the amount of movement that is required.

(17) Loosen the support bolts and shift the motor until the dial indicators read zero.

(18) Retighten each support bolt and check the dial indicators to make sure that the motor did not shift.

(19) Take a final set of dial indicator readings to verify that the alignment is within the tolerances specified for the equipment. Record the final set of readings on the data sheet.

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Graphing Horizontal Misalignment

“PH” and “ AH” values on data Sheet

Horizontal Misalignment

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Rim and Face AlignmentHorizontal Plane

2.5.2 Calculations for Horizontal Plane Misalignment

Using Formulas

As was done for the vertical plane, two formulas can be used to determine how much to move the motor to correct for angular and parallel misalignment in the horizontal plane. One formula is for the inboard feet and the other is for the outboard feet. The formula for the inboard feet is as follows:

XInboard = x AH - PH

D

The values for this formula are obtained from the data sheet. With the values from the example, the formula reads 12

Inboard = x (-5) - (+4) 10

Working through the math gives an answer of - 10 mils. When formulas are used, a positive answer indicates that the motor must be moved towards 3 o'clock. A negative answer indicates that the motor must be moved towards 9 o'clock. In this example, the inboard feet must be moved 10 mils towards 9 o'clock.

The formula for the outboard feet is as follows:

YOutboard = x AH - PH

D

The values for this formula are also obtained from the data sheet. With the values from the example, the formula reads

24Outboard = x (-5) - (+4)

10

Working through the math gives an answer of -16 mils. This means that the outboard feet must be moved 16 mils towards 9 o'clock.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


3- Reverse Alignment Method

3.1 Vertical Plane

3.1.1 Measuring and Correcting Vertical Plane MisalignmentIt is possible to measure misalignment in the vertical plane and the horizontal plane and then correct all the misalignments at the same time. If this is done, however, the movable component could be shifted accidentally in the horizontal plane while the vertical plane misalignment is being corrected. This type of shift would make the adjustments inaccurate. To minimise this possibility, many mechanics find it easier to align one plane at a time. This section of the program covers vertical plane alignment, which is typically done first.

3.1.2 MeasurementsThe first measurement is the horizontal distance between the stems of the two dial indicators.The second measurement is the horizontal distance between the "F" dial indicator stem and the centerline of the support bolt for the movable component's inboard foot.The third measurement is the horizontal distance between the “F" dial indicator stem and the centerline of the support bolt for the movable component's outboard foot. The measurements are all made parallel to the shafts.The tape measurements must be as accurate as a tape measure will allow, and they should be recorded on the data sheet. In the example under discussion, the first measurement is 6 inches; it is recorded on the data sheet as "D1”. The second measurement, labeled "D2” is 12 inches. The third measurement, labeled "D3” is 24 inches. After the tape measurements are taken and recorded, the pre-alignment procedures for this job are completed.

3.1.3

Data Sheet: Tap Measurements Recorded

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Tape Measurements

“F” Dial Indicator at 12 O’clock “ M” Dial Indicator at 6 O’clock

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3.1.3 Dial Indicator Readings

Readings are taken from both dial indicators and recorded on the data sheet

A- On the data sheet the "F" indicator reading is recorded at the 6 o'clock position.For this example, the reading on the "F" dial indicator is -6 mils.The reading is divided by 2 to account for the misalignment that was negated when the dial indicator was zeroed: (-6) 2 = -3

Data Sheet” “F” and “M” Dial Indicators Value and Calculation

To account for the bar sag measured earlier, the bar sag value of -1 must be subtracted. Subtracting a negative number is the same as adding a positive number: (-3) - (-1) = -2

The result of the subtraction is recorded in the box labeled “Fv.” “Fv” represents the amount of vertical misalignment measured by the "F" dial indicator.

B- The reading on the “M” dial indicator is recorded at the 12 o'clock position on the data sheet In this example, the reading is -16 mils. First, -16 is divided by 2 to get -8. Then, subtracting the bar sag value +1 leaves -9. This value is recorded in the box labeled “Mv.” “Mv” represents the amount of vertical misalignment measured by the "M" dial indicator.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


3.1 4 Graphing procedure (Reverse Alignment)

The following are steps involved in measuring, graphing, and correcting vertical plane misalignment.

(1) Complete the necessary pre-alignment preparations.(2) Rotate the “F" dial indicator to the 12 o'clock position and the 'M' dial indicator to the 6 o'clock position; zero both dial indicators.(3) Rotate both dial indicators 360 degrees; double-check for zero readings.(4) Rotate both dial indicators 180 degrees from their starting positions; record the readings on the data sheet.(5) Take another set of dial indicator readings (repeat step 4) to confirm that the

first set is accurate.(6) Perform the necessary calculations on the data sheet.(7) Plot a base point, “F," near the left side of the graph.(8) Plot point “M” by starting at “F” and moving to the right the value of “D 1" (from the data sheet).(9) Plot point “X” by starting at "F" and moving to the right the value of “D 2” (from the data sheet).(10) Plot point "Y" by starting at "F" and moving to the right the value of “D3”

(from the data sheet).(11) Plot the value of "Fv" from the data sheet. Starting at point "F," move up if the

value is positive or down if the value is negative. Label this point "Fv."(12) Plot the value of "Mv" from the data sheet. Starting at point "M," move up if

the value is positive or down if the value is negative. Label this point "Mv."(13) Draw a line through “Fv” and “Mv” On this line, plot point "Xv" by moving

straight up or down from "X." Plot point "Yv" by moving straight up or down from "Y."

(14) Factor in thermal growth, if necessary.(15) Count the number of increments between ”X” and "Xv" to determine how much to raise or lower the inboard feet. If "Xv" is below "X," raise the inboard feet by adding shims under the motor feet. if “Xv” is above "X," lower the inboard feet by removing shims.(16) Count the number of increments between "Y" and "Yv" to determine how much to raise or lower the outboard feet. If "Yv" is below "Y” raise the outboard feet by adding shims under the motor feet. If "Yv" is above "Y," lower the outboard feet by removing shims.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


3.1.5 The Graph (Cold Alignment)

To determine how much the motor must be moved to correct the vertical plane misalignment, begin at point "X" and move straight down the graph to the line that represents the centerline of the movable component's shaft. At this intersection, a point is made and labeled "Xv". Then the same thing is done beginning at point "Y" on the graph. The point on the centerline of the movable component's shaft that is directly below point "Y" is plotted and labeled “Yv.”

“XV” and “ YV” plotted on Graph

The number of increments between points "X" and "Xv" indicates how much the inboard feet of the motor should be moved. With this type of graph, when point "Xv" is below the horizontal line (the line representing the centerline of the fixed component's shaft) the inboard feet of the motor are raised. If "Xv" is above the horizontal line, the inboard feet are lowered. Also, the number of increments, and, therefore, the amount of corrective movement indicated on the graph, will apply toboth (or all, if there are more than two) of the motor's inboard feet.

The number of increments between points "Y" and "Yv" indicates how much the outboard feet should be moved. With this type of graph, when point "Yv" is below the horizontal line, the outboard feet should be raised. If "Yv" is above the horizontal line, the outboard feet should be lowered. The amount of corrective movement needed is the same for all of the motors outboard feet. In this example, to correct for misalignment in the vertical plane, the inboard feet must be raised 16 mils, and the outboard feet must be raised 30 mils.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


3.1.6 Formula Method For Reverse, Cold Alignment:

Another way to determine vertical plane corrections is to calculate the corrections mathematically using formulas. The calculations involve signed numbers

Two formulas are used together to determine how much to move the motor to correct for misalignment in the vertical plane. One formula is for the inboard feet of the motor, and the other is for the outboard feet. The formula for the inboard feet is as follows:

The values for this formula are obtained from the data sheet. For this example, the

formula readsWith this formula method, a negative answer indicates that the inboard feet of the motor should be raised to correct for misalignment in the vertical plane. A positive answer indicates that the inboard feet should be lowered. In this case, the inboard feet of the motor should be raised 16 mils to correct for vertical plane misalignment.

The formula for the outboard feet of the motor is as follows:

Plugging in the values from the data sheet, the formula reads 24 Outboard = (-9 –( -2)) + (-2) 6 = (-7) 4 + (-2) = (-28) + (-2) = -30 mils

The formula for the outboard feet is similar to the formula for the inboard feet. A negative answer means that the feet should be raised, and a positive answer means that the feet should be lowered. In this example, the outboard feet of the motor should be raised 30 mils to correct for vertical plane misalignment.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999

6


Reverse Dial Alignment Vertical Plane

3.1.7 Graphing Thermal Groth:

Thermal Growth ProceduresWhen determining how to factor thermal growth into an alignment, it is necessary to consider the signs of the thermal growth values. As shown on the data sheet, the pump has a thermal growth value of +5 mils. This means that the pump shaft is actually 5 mils higher at operating temperature than it is at ambient temperature. In this example, the motor has a thermal growth value of +2 mils, so the motor shaft is 2 mils higher at operating temperature than it is at ambient temperature.

Data Sheet showing Thermal Growth Values

Accounting for thermal growth involves adding or removing shims so that when the components reach their normal operating temperature, the two shafts will be aligned. There are two basic methods of determining the required thermal growth corrections: by using a graph or by using formulas.

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A- Cold Alignment Graph:

The graph can be used to illustrate how to begin graphing thermal growth corrections. In general terms, the two lines already plotted are redrawn to allow for the thermal growth values.

Cold Alignment Graph showing Vertical Plane Misalignment

B- Thermal Growth on Fixed Equipment Shaft:

First, the line representing the centerline of the fixed component (the line containing points "F," “M” "X," and "Y") is replotted. If the fixed component has a positive thermal growth value, the new line must be drawn above the existing one. If the fixed component has a negative thermal growth value, the new line is drawn below the existing one. In this example, the pump has a thermal growth value of +5 mils. Therefore, the new line for the fixed component is drawn 5 mils above the existing line to represent the position of the pump's shaft at operating temperature.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


Thermal Growth centerline of Fixed Components Shaft

C- Thermal Growth on Movable Equipment Shaft:

The next step is to plot the centerline of the movable component's shaft with the thermal growth value factored in. The thermal growth value of the motor in this example is +2 mils. Therefore, the new centerline is plotted by moving it 2 increments above the existing one (If the motor's thermal growth value were negative, the new line would be plotted below the existing one.) This new line represents the centerline of the movable component's shaft with thermal growth factored in.

Thermal growth Centerline of Movable Components Shaft

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


D- Correcting Misalignment Due To Thermal Growth:

To determine how much to raise or lower the inboard feet of the motor to allow for thermal growth, the increments between points "Xv" and "X" are counted. With this type of graph, if point "Xv" is below point "X," the motor feet have to be raised. If "Xv" is above "X," the motor feet have to be lowered. In this example, there are 19 increments between “Xv” and "X," so the inboard feet of the motor should be raised 19 mils.

To determine how much to raise or lower the outboard feet of the motor to allow for thermal growth, the increments between points "Yv" and "Y" are counted. (If "Yv" is below “Y” the motor is raised; if "Yv" is above “Y” the motor is lowered.) In this case, the outboard feet of the motor should be raised 33 mils to account for thermal growth.

In this example, raising the inboard feet of the motor 19 mils and the outboard feetof the motor 33 mils will account for both the misalignment in the vertical planeand the thermal growth characteristics of the pump and motor.

NOTE: When thermal growth is allowed for, the pump and motor shafts will be misaligned at ambient temperature; however, when the two components reach their normal operating temperatures, their shafts will be aligned.

3.1.8 Thermal Growth Calculations:

Instead of plotting a graph, the necessary thermal growth corrections can also be determined mathematically. This can be done in two basic steps:

(1) Subtract the thermal growth value for the movable component fromthe thermal growth value for the fixed component. In this example,(+5 mils) - (+2 mils) = +3 mils.

(2) Subtract the result of Step 1 from the cold alignment corrections.In this example, for the inboard feet, (-16 mils) - (+3 mils) = -19 mils. For the outboard feet, (-30 mils) - (+3 mils) = -33 mils.

As noted earlier, with this formula method, a negative answer means that the motor feet should be raised; a positive answer means that the motor feet should be lowered.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


3. Reverse Alignment Method

3.2 Horizontal Plane

3.2.1 Graphing procedures

The following steps are involved in measuring, graphing, and correcting horizontal plane misalignment.

(1) Measure and correct the vertical plane misalignment.

(2) Rotate the "F" dial indicator to the 3 o'clock position and the "M"dial indicator to the 9 o'clock position; zero both dial indicators.

(3) Rotate both dial indicators 360 degrees, double-check for zeroreadings.

(4) Rotate both dial indicators 180 degrees from their starting positions;record the readings on the data sheet.

(5) Take another set of dial indicator readings (repeat step 4) to confirmthat the first set is accurate.

(6) Perform the necessary calculations on the data sheet.

(7) Plot a base point, "F," near the left side of a graph. Draw a straightline across from “F”

(8) Plot point "M" by starting at "F" and moving to the right the value of"D1” (from the data sheet).

(9) Plot point “X” by starting at "F" and moving to the right the value of“D2” (from the data sheet).

(11) Plot point "Y" by starting at "F" and moving to the right the value of “D3” (from the data sheet).

(11) Plot the value of ”Fh” from the data sheet. Starting at point "F," move up if the value is positive or down if the value is negative. Label this point ”Fh.”

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


(12) Plot the value of "Mh" from the data sheet. Starting at point "M," move up if the value is positive or down if the value is negative. Label this point "Mh".

(13) Draw a line through "Fh” and "Mh." On this line, plot point "Xh" by moving straight up or down from "X." Plot point "Yh" by moving straight up or down from "Y."

(14)Count the number of increments between “X” and "Xh" to determine how far to shift the inboard feet of the motor in the horizontal plane.

(15)If "Xh" is above "X," move the inboard feet of the motor toward 9 o'clock; if "Xh" is below "X," move toward 3 o'clock.

(16)Count the number of increments between “Y” and "Yh" to determine how far to move the outboard feet of the motor in the horizontal plane. If "Yh" is above "Y," move the outboard feet toward 9 o'clock; if "Yh" is below "Y" move toward 3 o'clock.

“Xh” and “Yh” Plotted on Graph

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3.2.2 Correcting The Misalignment using The Graph:To determine how much the motor must be moved to correct the horizontal plane misalignment, it is necessary to move straight up from point "X" and mark a point on the line just drawn. This point is labeled "Xh." A similar mark is then placed on the line moving up from point “Y". This point is labeled "Yh.”. The motor's movement is determined by counting the increments between "X" and "Xh" and between "Y" and "Yh." "Xh” has a value of 28 mils, and "Yh" has a value of 36 mils.

To correct for the horizontal plane misalignment, the motor's feet are moved toward the 3 o'clock or 9 o'clock position. With the type of graph shown in values below the horizontal line represent the amount of movement needed toward the 3 'clock position. Values above the horizontal line represent the amount of movement needed toward the 9 o'clock position. The distance between "X" and "Xh" is the amount of movement needed for the inboard feet, and the distance between “Y” and “Yh” is the amount of movement needed for the outboard feet. In this example, to correct for the horizontal misalignment, the inboard feet must be moved 28 mils toward the 9 o'clock position, and the outboard feet must be moved 36 mils toward the 9 o'clock position.

3.2.3 Formula Method:

To calculate mathematically how much to move the motor to correct for misalignment in the horizontal plane, two formulas are used together. One formula is for the inboard feet of the motor, and the other is for the outboard feet. The formula for the inboard feet is as follows:

The values for this formula are obtained from the data sheet. For this example, the formula reads:

= (+ 4) x (+2) + (+20) = (+8) + (+20) = +28 mils

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


With this formula method, a positive answer indicates that the feet of the motor should be moved toward the 9 o'clock position; a negative answsr indicates that the feet should be moved toward the 3 o'clock position. In this example, the inboard feet of the motor should be moved 28 mils toward the 9 o'clock position.

The formula for the outboard feet of the motor is as follows:

Plugging in the values from the data sheet, the formula reads:

= (+4) x (+4 + (+20) = (+16) + (+20) = +36 mils

Once again, a positive answer means that the motor feet should be moved toward the 9 o'clock position; a negative answer means that the motor feet should be moved toward the 3 o'clock position. In this example, then, the outboard feet of the motor should be moved 36 mils toward the 9 o'clock position.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


5- Training Aids

1- Video tape (Shaft Alignment- 1)

2- White Board.

3- Transperencies

T Description Transperencies Page

T1 Course Objectives 4

T2 Alignment Orientation 10

T3 Reading Measurements 17

T4 Graphing Vertical Plane (Rim & Face) 19

T5 Graphing Thermal Growth (Rim & Face) 21

T6 Graphing and Thermal Growth (Rim & Face) 22

T7 Graphing Horizontal Plane (Rim & Face) 28

T8 Measurements for Reverse Alignment 31

T9 Dial Indicator Readings (Reverse A.) 32

T10 Cold Alignment Graph (Reverse A.) 34

T11 Graphing Thermal Growth (Cold Graph) 37

T12 Graphing Thermal Growth (Fixed Equipment) 38

T13 Graphing Thermal Growth (Movable Equipment) 38

T14 Graphing Horizontal Misalignment (Reverse) 41

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


6- Lesson Plan

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


Lesson Plan

Lesson One (6 Hrs)

Objectives: Understand orientation upon performing alignment. Demonstrate pipe strain correction. Perform soft foot. Explain run out reading. Understand thermal growth. Ex-plain setting the face gap. Demonstrate mechanical centre. Demonstrate magnetic centre. Perform bar sag.

Content ActivityIntroduction

Instructor. Participants. Course objectives.

Lesson 1- Preparation for AlignmentA. 1.1- Definition.

1.1.1 Alignment Orientation.1.2 Equipment Preparation.1.2.1 Pipe strain.1.2.2 Soft foot condition.1.2.3 Taking run out reading.1.2.4 Measuring thermal growth 1.2.5 Setting the face gap.1.3 Determine Mechanical Center.1.4 Determine magnetic centre.1.5 Measuring bar sag.

B. Guide the participants to W/S for demonstration.

C. Free discussion.D. Assessment.

Show T1 for course objectives.

Explain on the white board.Show T2 for orientation.

Show Video tape for Shaft Alignment (One hour)

Allow for 4 hours in W/S.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


Lesson One Assessment

1- What is the first preparation for a shaft alignment job, as a safety procedure?

2- How can you make sure that the foundation that supports the pump and the motor is level?

3- What is the pipe strain?

4- Define the soft foot?

5- What is the thermal growth?

6- Why is it necessary to have a gap between the face of the hubs?

7- What is the axial movement?

8- What is the magnetic center in a motor?

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


Lesson Plan

Lesson Two (9 Hrs)

Objectives: Understand the measurement procedure (vertical plane). Understand the graphing procedure. Understand using formulas. Understand graphing thermal growth. Understand using formula for thermal growth. Explain graphing procedure (horizontal plane). Explain horizontal alignment using formula.

Content ActivityLesson 2: Rim and face alignment.

* Vertical Plane.A. 2.1 Measurement procedures.

2.2 Graphing vertical plane misalignment.2.2.1 Graphing procedures.2.3 Using formula.2.4 Graphing thermal growth.2.4.1 Graphing procedures.2.4.2 Graphing and correcting vertical plane misalignment (thermal growth)2.4.3 Calculation of vertical plane misalignment using formula.* Horizontal Plane.2.5 Graphing horizontal plane misalignment.2.5.1 Graphing procedure.2.5.2 calculation for horizontal plane misalignment using formula.

B. Guide the participants to W/ S to demonstrate and perform Rim and face alignment.

C. Free discussion.D. Assessment.E. Housekeeping.

Show T3 for readings and measurements.Show T4

Show T5 , T6

Show T7

Show video tape (Shaft Alignment one hour)

Allow for 6 hours in the W/S

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


Lesson Two Assessment

1- What is the effect of equal thermal growth for fixed and movable equipments when graphing misalignment?

2- What does the base line on an alignment graph represent?

3- What does the graduation on a typical alignment graph represent on the vertical and horizontal lines?

4- On the graph below, what does the dashed line “ XAP” – “YAP” represent?

5- How do you for correct misalignment in the vertical plane of a movable equipment?

6- What is the effect of a bar sag, during the performance of a misalignment in the horizontal plane.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


7- What do you do to correct the horizontal misalignment?

8- How many increments are needed to move the motor shaft to be aligned on the graph above?

9- Why is it important to take a final set dial indicator reading after an alignment is completed?

10- Use values from data sheets pages 22 & 28 Determine how much and in what direction to move the motor feet in order to correct for both angular and parallel misalignment in the vertical and horizontal planes. Correct for thermal growth.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


Lesson Plan

Lesson Three (9 Hrs)

Objectives: Understand measurement procedures. Understand graphing procedures. Explain using formula the alignment. Explain correcting misalignment due to the thermal growth. Explain graphing procedure for horizontal alignment. Explain formula method for horizontal alignment.

Content ActivityLesson3 : Reverse Alignment Method.

A. 3.1 Vertical Alignment.3.1.1 Introduction.3.1.2 Measurements.3.1.3 Dial Indicator Readings.3.1.4 Graphing procedures.3.1.5 the cold alignment graph.3.1.6 Formula method.3.1.7 Graphing thermal growth.3.1.8 thermal growth calculations.3.2 Horizontal Plane.3.2.1 Graphing procedures.3.2.2 Correcting misalignment using the graph.3.2.3 Formula method.

B. Guide the participants to the W/S to demonstrate and perform.

C. Free Discussion.D. Assessment.E. Housekeeping.

Show T8 & T9

Show T10

Show T11 & T12 & T13

Show T14

Allow for 6 hours at the W/S

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


Alignment

Lesson Three Assessment

1- What are the initial positions for “F” & “M” dial indicators on reverse alignment?

2- On the graph above, answer the following:a. Define the distance between “M” & “Mv”.b. Define the distance between “F” & “Fv”.c. Define the distance between “X” & “Xv”.d. Define the distance between “Y” & “Yv”.e. Define the distance between “X” & “F”.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


3-On the graph above. How many mils does the inboard foot of the motor have to move in order to align with the pump?

4- How can you correct for vertical plane misalignment for the board foot on the graph?

5- Calculate the following:a. (-6) – (-9) =b. (+9) – (-19) =c. –(10) – (+1) =d. (+13) - (21) =e. (-94) – (-5) =

6- What is the thermal growth for the rotating equipment?

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


7- On the graph below, answer the following questions:-a. Measure the distance between points “F” & “Fh”?b. Measure the distance between points “Y” & “F”?c. Measure the distance between points “M” & “Mh’?d. Measure the distance between points “X” & “Xh”?e. Measure the distance between pints “UY” & “yh”?

8- a) What do the values below the horizontal line represent?b) What do the values above the horizontal line represent and in what direction are they?

9- What is the line between points “Fh” & “Yh” represent?

10- Correct the horizontal lane misalignment on the graph.

11- Where would you graph point “Fh’ = +20 mils? (mention only below or above pint “F”)

12- Given the data sheet next page, determine how much and in what direction to move the motor feet in order to correct for both angular and parallel misalignment in the vertical and horizontal planes?Correct for thermal growth.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


Answers

Lesson One Answers:

1- Making sure that the equipment being aligned is isolated and tagged out.2- By using bubble level at different point on the skid.3- The force exerted on a component from a bent shaft or a mis board hub.4- A condition exists when one or more of the movable components feet are in

different planes.5- The physical movement that occur as a piece of rotating equipment reaches

its normal operating temperature.6- To allow a room for axial movement of the shaft without damaging the hub

and coupling.7- The amount of shaft movement back and forth along the axis of the shaft.8- The position of the motor shaft caused by the magnetic field during

operation.

Lesson Two Answers:1- No effect.2- The position to which the movable component must be moved in order to

eliminate misalignment.3- Vertical graduation one mils, Horizontal graduation one inch.4- Angular and parallel misalignment in the vertical plane.5- Add or remove shims under the feet of the movable component.6- No effect.7- To move the motor towards 3 or 9 o’clock.8- In board 11 mils, out board 17 mils towards 9 o’clock.9- The final set of reading is needed to make sure that the alignment is within

specified tolerances.10- Solution on page 57.

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IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


Answers

Lesson Three Answers:

1- “F” dial indicator at 12 o’clock, “M” dial indicator at 6 o’clock.2- a. The amount of vertical misalignment measured by the “M” dial indicator.

b. The amount of vertical misalignment measured by the “F” dial indicator.c. The amount to move the in board foot of a motor to correct for vertical plane misalignment.d. The amount to move the out board foot of the motor to correct for vertical plane misalignment.e. the distance between the stem of the “F” dial indicator and the centerline of the support bolt for the in board foot of the motor.

3- Remove 11 mils shims.4- Remove 17 mils shims.5- a) +3 , b) +38 , c) –11 , d) –8 , e) –89.6- The movement that occurs as rotating equipment reaches its normal

operating temperature.7- a) 10 mils, b) 26 inches, c) 12 mils , d) 15 mils , e) 1`9 mils.8- a movement needed towards 9 o’clock position.

b. Movement needed towards 3 o’clock position.9- The center line of the movable component shaft.10- Move in board foot 15 mils towards 9 o’clock position and out board

foot 19 mils towards 9 o’clock position.11- Above.12- Solution on page 59.

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IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


Final Assessment (Classroom)

Determine how much and what direction to move the motor feet in order to correct both angular and parallel misalignment in the vertical and horizontal planes- use graph and formula. Correct for thermal growth in the given data sheet for:-

1- Reverse alignment.2- Face and rim alignment.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999


Final Assessment (Practical)

Perform alignment using Rim and Face methods. Use graphing and formula. Perform alignment using reverse alignment method. Use graph and formula.

IHRDC AL – M - 02 (Rev - 0) 02 – 2 – 1999

alignment module

Documents

horizontal alignment

rim alignment

alignment orientation

alignment job

methods of shaft alignment

course objectives

course program

course outline