ALIGNMENT COURSE.pdf

8/10/2019 ALIGNMENT COURSE.pdf

1/29

ROTATINGEQUIPMENTDEPARTMENT

EGYPTIANNITROGIENPRODUCTSCOMPANY

DOCUMENTNO. REV. Pages

Alignment

Training

Course

Prep.BY

ENG.HaithmMohamedSabry

Rotatingequipmentsengineer

ENPC

H.sabry H.mikky H.mikky

DATE DESCRIPTION

PREP,D CHK

,D APP

,D

COMPANY


2/29

r

lignmen

heprima

otating

ONSEQU

a) Pre

b) Exc

c) The

cou

d) Loo

e) Loo

: is to

sameli

ryobjecti

achinery.

ENCESO

atureb

ssive

am

shafts a

pling

hub

sefounda

seorbro

ake

the

ne(com

eofacc

DEFECTI

aring,se

unt

of

lu

re breaki

.

tionbolts

encoupli

centre

lin

oncentr

ratealig

EALIGN

l,shaft,

bricant

le

ng (or cr

,typically

ngbolts

e

for

the

line)atn

mentist

MENT

rcouplin

akage

at

acking) a

causedb

embran

drive

an

ormalop

increas

failures

he

beari

t or clos

yasoft

d

driven

rationco

theoper

g

seals

e to the

ootcon

coupli

machine

ndition.

atinglife

inboard

dition

g

rotor

at

t

spanof

bearings

-1

2-

-3

he

or


3/29

I

t

HATHA

thealig

oeachot

ypesof

isalignm

a) Par

b) Ang

c) Co

isalign

a) Ver

b) Ver

c)Hor

d)Hor

PPENST

mentisi

herevery

isalignm

ent(divis

lleloffse

ularmisal

bined

mi

entthro

icaloffse

icalangu

izontal

of

izontal

an

ROTATI

noredth

revolutio

ent

ionfrom

misalign

ignment

salignme

ghoner

misalign

larmisali

set

misal

gular

mis

GMACH

ebothsh

n.

ommon

ment

t

volution

ment

nment

ignment

lignmen

INERYW

ftsandc

entrelin

isclassifi

ENITIS

ouplingh

)canbe

edtofou

ISALIG

lveswill

allofthe

compon

ED

lexorbe

threefor

ents

ndrelativ

ms

e


4/29

Thefollowingtoolsmaybeusedinshaftalignment:

Dialindicator

Magneticbase

Feelergauges

Micrometer(in

out)

Straightedge

Mirror

Spiritlevel

Torquewrench

Marker

Sandpaper

Plastichummer

Togetaccurate finalcouplingalignmentwemustknow theparameters thatmustbe

eliminated for every participate part component that may be affect the quality,

accuracyofthealignment.

1.Pumpmotorskiddistortionandwrapping

2.Themotor:

a) Softfeet

b)Holddownboltsandstuds

c) Basepadsandshims

d) Jackingbolts

e) Cablestrain

3.Thepump

a) Pipingstrain

b) Pumpsupportstrain

4.

Shaftandcouplinghubs

a) Runout

b) Endplay(axialfloat)

5.Usedtools

a) Dialindicator

b) Alignmentfixturesag

6.

Environmentssun

light


5/29

s

t

1.Pu

fterposi

uction a

ransvers

oltssob

2.Th

a) Sof

eansth

olding

ovingth

hetypes

pmot

ionthep

d discha

lyadjust

thiselim

motor

feet

machin

ownbolt

ebearing

ofsoftfo

rskidb

umpskid

rge flang

the level

inateany

e

will

n

tightene

housing,

tarepar

sefram

onthefo

e and th

of the s

wrappin

t

sit

on

dthe fee

thebeari

allel,ang

edistor

undation

e motor

idbyjac

inthesk

its

feet

willbe

gandth

larorco

ionand

byusing

sole plat

k screwa

idandhe

Jacksc

robably

lamped

shaftth

binatio

wrappi

piritleve

es levell

nd shims

nceanys

rew

and

wil

owndist

salterin

.

g

l(0.02m

d longit

around

urcefor

anch

l

wobbl

ortingth

thealign

/m)ont

dinally a

achanc

oftfeet.

rbolt

when

t

framea

ment.

he

nd

or

he

nd


6/29

ft

oftfeetc

oft feet c

oftfoot

y using

ounted

nlyparall

eeleror

or

makinhebase,

a) Ens

and

b) Inst

c) Try

d) Ang

on

ondition

n be foun

heck:

eeler ga

onamag

lelsoftfo

taperga

check

frimaryc

rethatt

rust.

allthem

opassfe

ularsoft

ithersid

.

d in three

ges or t

neticbas

t.

gesare

r

insert

seckforn

ebotto

torinpla

elergaug

aybea

onthe

basic con

aper gau

eordial

otaccur

hims

undewmachi

ofthem

cewitho

esunder

justedby

etalshim

itions.

es for b

indicator

teasusi

er

the

unnes

achinesf

ttighten

achfoot

usingste

sassho

oth paral

mounted

gdial in

supporte

etandt

thefeet

tocheck

ppedshi

n.

lel and a

on thec

icators

spaces

ebasefr

arallelo

sorbyu

ngular, di

ouplinga

owevert

etween

efromd

angular

singelast

al indica

ndshaft

heycan

he

feet

a

irtburrs

oft

mershi

or

or

se

nd

s


7/29

I

the ma

iagonal

ndereac

ialindic

a)

Firsb) Tig

c) Set

d) Loo

e) Ifth

the

f) Rep

att

ialindic

a) Firs

b) Tig

c) Rot

d) Loo

e)Reti

f) Sel

g) Che

hine wo

oot hold

hfoot.

torand

check

ating

all

h

upthedi

sethebol

ereading

foot.

eatthes

eendof

tormou

checka

tenallho

tethesh

seeachf

ghten

th

ctthehei

ckagaint

bble on

down ag

agnetic

d

correct

ld

down

lindicato

tandobs

isexcee

meproc

work.

tedinth

dcorrect

lddown

aftsothe

otando

foot

agai

ghtreadi

hefeeta

iagonal

ainst the

asetoc

for

angulbolts

to

c

rontop

ervethe

s0.05m

durefor

couplin

forangul

oltstoc

dialislo

serveth

n

and

re

ngandpu

cordingt

eet, mea

base an

eckever

ar

soft

forrect

tor

fonefoo

ial.

putshi

achfoot

hub

arsoftfo

rrecttor

atedatt

reading

eat

the

s

tabout8

heabove

sure the

shims

footisr

t

using

fque.

t.

swithth

anddon

tusingf

ue.

etopce

nthehu

me

steps

0%ofdial

steps.

gap und

quivalen

stingon

eler

gau

esamea

forgetto

elergau

tre(12:0

b.

to

every

readingv

r one fo

to the

hebase.

e.

mountan

checkfin

e.

).

foot.

alue.

ot with t

alf the g

retighte

alsoftfo

he

ap

n

t


8/29

f

b)Hol

hould b

ovemen

rindingb

oles.

c) Bas

hebase

ounting

ndshims

d) Jac

hejack

inal

aligxpansion

downb

sufficie

t

during

utbe car

padan

padshoul

and the

.

ingbolts

oltmust

ed

the

direction

ltsands

t cleara

lignment

efuldon

Shims

dbefree

lotshoul

sitsquar

olts

muduringn

tuds

ces in t

work,

m

tweak t

ofburr,

dbe larg

lyandp

t

releasrmalope

e hole i

unting

b

eboltor

irtandf

erenoug

shthef

to

protrationso

n the m

lts

can

b

by soft

latconta

toavoi

etwitho

ect

the

itcanaff

chine fe

e

reduce

grinding

,shimss

contact

tliftingi

machine

ctinthe

et to all

in

diam

for the

houldbe

between

;oncet

from

un

verticalal

w side

ter

by

lit

achine f

slotforf

bolt thre

emachin

expectaignments

ay

tle

et

ee

ad

ed

le

.


9/29

f

f

t

i

f

e) Cab

omehig

lignment

3.

Tha) Pipi

fterpro

orgroute

he obje

achiner

istortion

ailure

ev

ot that

hepiping

nsuretha

ecomme

Pip

mm

The

the

Fla

Onl

hebasic

lange

whi

lestrain

ratedm

pumpngstrain

erlevelli

d.Afterg

tive of

are

min

onshafts

n

shaft

al

esidemi

duringo

thepip

ndationt

flangeb

maximu

machine

pipe

flan

gefaces

onegas

methodo

le

measu

torhave

gskida

routfinis

iping ali

imized.

L

,bearing

ignment

i

salignme

peration

upporto

oavoidp

ltshole

offset

f

andpipin

e

outer

d

paration

etperfla

fverifyin

ing

the

d

rigidand

dcouplin

edthem

nment t

ess

strain

housing.

s

achieve

tpipe, t

and the

thepipi

ipingstra

hallbeli

om

the

c

gflanges

iameter

f

shallbe

ngedcon

pipstrai

eflection

bigcable

gprealig

achinere

verify

impose

So ifthis

while

pi

ermalm

eight f t

g.

inonthe

edupwi

nter

of

t

facessha

or

flanges

ithinthe

nections

nconsist

f

the

ma

itmustb

nmentro

leasefor

hat strai

on

the

false loa

p

strain

e

ovement

he fluidc

machine

thmachi

e

bolt

ho

llbepara

above

1

gasketsp

allbeus

ofboltin

chine

sha

takein

ughlych

ipingact

ns impos

machine

ingcanr

ists.

(expansi

ausingpi

casing(A

erynozzl

le.

lleltoles

inch

ma

acingplu

d.

gupthe

t

with

di

inedits

ckthesk

ivities.

ed by th

casing

re

esultinr

nandco

pestrain

I686)

eboltsh

than0.

imum

of

orminu

ipingto

l

indicat

ffecton

idisrele

piping

sults

in

l

pidbeari

ntraction

sowem

leswith

1mm/cm

0.75

mm.

1.5mm

hemachi

r.

se

on

ss

ng

of

st

.5

of

ne


10/29

t

s

t

hreedial

asetoo

he

bigger

ne

methnesideo

b) Pu

orcentri

nd tight

hims

as

t

4.Sh

a) Run

unoutis

fthefirs

wobasic

indicato

serveth

flange

di

od

commrremove

psuppo

ugalpu

againwhi

he

same

ftandc

out

alsorefe

thingst

ypesofr

should

horizont

meter.

only

usedtheweldi

tstrain

pswith

leobser

alue

and

upling

redtoas

checko

unoutco

emount

aloffset

to

correngcapan

earingh

e thedia

check

aga

P

ubs

anoffc

nthema

nditions,

ed to re

uringtig

t

the

pipdreweld

ousingsu

l indicato

in

ump

type

nteror

hineryt

adialand

d facea

htenthe

flange

again.

pportOH

r if thed

H1

eccentri

atisatte

facerun

d rima

langesit

isaligned

1 loose t

ial read

conditi

mptedto

out.

ddialwi

sprefert

by

heati

he suppo

bove0.0

onandsh

bealign

hmagn

ostartfr

g

part

fr

rt twob

25 then

ouldbeo

dThere

tic

m

m

lts

ut

ne

re


11/29

s

I

I

i

henper

haftsrot

nly

the

its

diffietweent

utcheck

any run

achined

b) End

henper

eheldat

ount

di

bservet

orrotor

n

accoun

otothe

forming r

tearero

isalignm

cult

to

rheruno

priortot

Th

outexist

or

discar

play(axi

ormingri

thesam

l

on

the

ereadin

ithslee

.

For

exa

agnetic

imand f

tate360

nt

betwe

tate

the

tormisal

eactual

ee

basic

ty

smore t

ed.

lfloat)

mandfa

ofitsax

haft

or

c

onthed

ebearin

ple

elec

enterw

cealign

byrotati

en

the

sh

shaft

of

lignment

alignmen

es

of

run

ou

an0.25

cereadin

ialtravel

upling

f

ial

thenor

tric

moto

enthefi

ent the

ngthet

afts.

tationarothefirs

t

problems

mbent

oradju

whilefac

ce

and

p

alopera

r

with

ar

ldisappl

dial indic

oshafts

machinetstepist

ith

shafts

a

hafts,co

ttheDB

reading

ush

the

r

tingposit

ature

su

ied.

orsares

hetwo

,

the

dialocheckt

nd

coupling

uplingsh

Eaxialsp

istakent

tor

to

e

ionofth

pported

etat12,

ialwillo

cannot

heshaft,

hubs

uldbes

acing th

ocheckt

ch

side

s

rotorm

n

sliding

3,6,9.b

ly indica

ifferentiouplingr

raighten

shaftm

heendfl

veral

ti

stbetak

bearing

th

es

te

un

d,

st

at

es

en

ill


12/29

t

t

r

ompressheirroto

hiswesh

5.Us

a) Dial

henusi

eingche

ot

set

sq

unthrou

henthe

eat90t

r

and

tusshould

oulduset

dtools

indicato

g adial

ked,isi

uare

to

t

hthece

dialindic

othefac

bine

will

beheld

wodiali

indicator,

portant.

he

directi

trelineo

atorispl

operate

gainstth

dicatorf

theposi

Theaccu

on

of

the

theshaft

cedont

gainst

acactives

rfacere

tion that

racyoft

movem

orcoupli

efaceof

ive

thrusideprior

dingpri

thedial

edialin

nt.

The

ng.

thecoup

t

bearing

osetting

aryands

is set, in

icatoris

entrelin

lingorhu

during

ththeaxial

econdary

relation t

reatlyaf

of

the

p

b,theplu

e

alignmspacing

o thepi

ectedifi

lunger

m

ngersho

nt

or

ce

is

st

ld


13/29

(

r

r

b)Alig

hich is

ovemen

hereare

i. The

bar

ii. The

iii. The

iv. Cla

oldthea

ar,andd

Particula

eadings.

eadings

h

nmentfi

movemen

tthataff

fourfact

amount

spanoft

stiffness

pingfor

ssemblyi

ialindicat

ly

at

the

sually,t

ave

a

neg

turebrac

t, or ben

ctsthea

raffect

t

foverh

ebar

f

the

ba

eofthe

nthehori

orassem

ottom)

a

ereadin

ative

val

ketsag

ding, in t

curacyo

heamou

ungweig

racketto

zontalpo

lythrou

nd

record

soneac

e

(typical

he rod d

thereadi

tof

brac

t(weight

theshaft

sitionan

h90arc

what

yo

sideare

ly).

ue to gr

ngs.

ketsag.

ofthedi

rotatet

sandnot

see.

The

halfofth

vityDial

l indicat

eentire

therea

se

are

ref

bottom

bar sag i

ratthe

ipe,brac

ingsate

erred

to

readinga

s unwant

endofsp

ket,span

chpositi

s

the

sa

ndalloft

ed

an

n

he


14/29

r

t

I

ocompe

ottom r

eading.

ethod.

6.

En

e

caref

emperat

sprefer

nsatefor

ading an

ut we w

ironme

l

that

t

reinside

toworku

thesag,

d the am

ill discuss

tsun

li

hat

whe

pipingan

ndercov

ddthea

ount of t

simple

ht

perfor

dthecasi

rorshelt

ountof

he sag o

ethod t

ing

alig

ngaffect

ertoavoi

thesago

bserved

compe

nment

u

andchan

dthis.

bserved

n the e

sate the

nder

su

etheali

tthebot

ch side t

sag in ri

s

light

nmentre

omtoe

o each si

m and f

the

soak

adings

ch

de

ce

ed


15/29


16/29

Prealignmentchecks.

As explained in the previous chapter several things causemisalignment, and should

alwaysbecheckedbeforebeginninganalignment. Theyareasfollows:

1.

Pumpmotor

skid

distortion

and

wrapping

2. Themotor:

a) Softfeet

b)Holddownboltsandstuds

c) Basepadsandshims

d) Jackingbolts

e) Cablestrain

3. Thepump

a) Pipingstrain

b) Pumpsupport

strain

4. Shaftandcouplinghubs

a) Runout

b) Endplay(axialfloat)

5. Usedtools

a) Dialindicator

b) Alignmentfixturesag

Thefourstepsofanyalignmentare:

1. Removeverticalangular(face)misalignment.

2. Removeverticalparallel(heightupanddown)misalignment.

3. Removehorizontalangular(face)misalignment.

4. Removehorizontalparallel(sidetoside)misalignment.

Aftersteps1and2,andshimming(theaddingorremovingofshims)iscompleted,steps

3and4aredoneatthesametimebymovingthejackbolts(sidewaysmovement).

Methodsofalignment.

1. Straightedgeandfeelergauge.

2. Rimandface(dialindicator).

3. Crossdialorreverseindicator(dialindicator).

4. Graphicalmethod.

5. Laseralignment.

Inour

course

we

will

concern

on

the

rim

and

face

by

using

straight

edge,

dial

indicator

methodstheyalwaysusedmorefrequentlyinourwork.


17/29


18/29

2. Dial

herima

rfaceof

hisisag

erotate

heface

othverti

irectlyre

emembe

indicato

dfacem

acouplin

oodtech

oritwo

ialreads

alandh

latedtot

rthemat

method

ethodus

hub.Th

iqueto

ldbediff

theamo

rizontal

ediame

hematical

stwodia

otherdi

seinsitu

iculttoro

ntofang

lanes. B

erthefa

lformula.

lindicato

lreadso

ationsw

tateone

ular(axia

causeof

ereadin

rs. Oneis

ftherim

ereone

fthema

l)misalig

theangle

saretak

mounte

oftheco

fthema

chinerys

mentat

theaccu

n.

toread

pling.

chinerys

afts.

0tothe

racyofth

ffthefr

aftscan

shaftaxis

ismetho

nt

ot

in

is


19/29

The rimdial reads theamountofparalleloffsetmisalignment from the shaftaxis in

boththeverticalandhorizontalplanes.

It is important that the dials are read in the same position every time. That is, four

positionsat90 toeachother. Thesepositions shouldbe read in thesamewayasa

clockface;

12

oclock,

3oclock,

6oclock,

and

then

9oclock.

They

are

viewed

from

behindtheM.T.B.S(movablemachine)machinetobeshimmed.

Procedure:

1. Attachthealignmentbracketfirmlytooneshaftnormallythemovablemachine

and position the indicators on the face and rim surface of the other shaft (or

couplinghub).

2. Zerotheindicatorsatthetwelveo'clockposition.

3. Slowly rotate theshaftandbracketarrangement through90 Intervalsstopping

atthethree,six,andnineo'clockpositions.Recordeachreading(plusorminus)

remembertosetthesmallclockin5toeasyfollowthemainindicator

4. Returntothetwelveo'clockpositionto12toseetheindicatorrezeroreading.

5. Repeatsteps2through4toverifythefirstsetofreadings.

Theruleisthetotalreadingoftopandbottomequalrightandleft.

Thesumofthetwomeasurementsonbothsidesofzeroshouldequalthemeasurement

thatisoppositeofthezero.


20/29

Whyrimreadingstwicetheactualoffsetexplain?

Whentakethereadingfromonesidetotheotheronashaft,thetotalamountthatthe

indicator(oranymeasurementsensor)observesistwicetheamountthatthe

centrelinesofrotationareactuallyout

Rimandfaceformula.

Tousetherimandfaceformula,itisimportanttoknowwhichmeasurementsaretaken

andwhere.

D=diameterofthepaththefacedialwilltravel.

S1=shimpackingforthefrontlegs(+/)signindicatesaddorremoveshims.

S2=shimpackingforthebacklegs.

TIR=totalindicatorreading.

L1=length(paralleltothecentrelineoftheshaft)fromwherethedialsareread,tothe

firstholdingdownbolt.

L2=length

to

the

rear

holding

down

bolt.


21/29

Formulaforcorrectionofaxialandradialmisalignment...

S1L1

DTIR(face)

TIR(rim)

2

S2L2

D

TIR (face)TIR (rim)

2

Note: TIR(rim)/2arethetotalindicatorrimreadingdividedbytwo.

This determines the actual amount of radial offset misalignment.

ProcedureSummary

1. Perform pre-alignment checks.

2.Align approximately using rule and straight edge. If the space enough.

3.Attach dial indicators to flange of motor and position one dial at 12 oclock on thepump rim and one at the top of the pump face.

4. Measure the following dimensions carefully.

D Diameter of Pump Flange.

L1 Distance from Pump Flange to Front Foot of Motor.

L2 Distance from Pump Flange to Back Foot of Motor.

5. Push flanges to back positions to eliminate end float and set the two dials to zero.

6. Rotate both flanges at 900intervals making sure the flanges are pushed back each

time and record the dial readings.

7. Rough horizontal face and radial offset. This will reduce inaccurate verticalreadings. It will also reduce the number of times that the shims have to be inserted

8. Using the formula find the amount of shims to remove or add to eliminate verticalmisalignment.

9. Reset the dials to zero at the 3 oclock position and repeat step 6 (horizontalreading).

10.Using the formula find the amount of movement required to eliminate horizontalmisalignment.

11.Place the magnetic base and dial indicators of the sides of the front and back legs.Set to zero and move the motor to the required amount using the jack screws.


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1. PreciseHorizontalalignment


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2. PreciseHorizontalalignment

Planviewofthemachineinsteadofanelevation.Jackingboltsareshowntofacilitythe

horizontalmovementofthemachine.

H1=L1/D*TIR(face)TIR(rim)/2

H2=L2/D*TIR(face)TIR(rim)/2

Datumsideis3clocksorzerostartpointandtakea180bythedialsoTIR(face)isthe

resultantreadintheindicatoron9clocks.


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Documents

ALIGNMENT COURSE.pdf