Title: ALIGNMENT
1ALIGNMENT
21- Introduction
3What is shaft alignment
It is collinear of two center lines
Shaft alignment is the proper positioning of the
shaft centerlines of the driver and driven
components (i.e., pumps, gearboxes, etc.) that
make up the machine drive train. Alignment is
accomplished either through shimming and/or
moving a machine component. Its objective is to
obtain a common axis of rotation at operating
equilibrium for two coupled shafts or a train of
coupled shafts.
4Why it is important to make shaft alignment?
Shafts must be aligned as perfectly as possible
to maximize equipment reliability and life,
particularly for high-speed equipment. Alignment
is important for directly coupled shafts, as well
as coupled shafts of machines that are separated
by distance spool (those using flexible
couplings). It is important because misalignment
can introduce a high level of vibration, cause
bearings to run hot, and result in the need for
frequent repairs. Proper alignment reduces power
consumption and noise level, and helps to achieve
the design life of bearings, seals, and couplings.
52-Types Of Couplings
61 -Rigid Couplings It is a metal to metal
contact (100 collinear)
2 -Flexible Couplings Spacer with shims
Gear Grid Rubber Others Torque converter
Alignment
7It is collinear of two center lines
Motor
Equipment
Coupling
8Pump Grouting
Special grouting concrete
91 -Rigid Couplings
Driver
2 Flexible Couplings
Spacer with shims
10Spacer with shims
11Spacer with shims
Spacer is not connected directly to both hubs,
but through the shims
Driver
Equipment
12Gear
13Grid
14Torqueconverter
15Pumps
Turbine
MOTION
MOTION
HYDRAULIC ENERGY
HYDRAULIC ENERGY
16Normal speed
Higher speed
Lower speed
17Guide Vanes
183- Alignment Preparation check list
19Alignment Preparation check list
Comments
Description
N/A
OK
20Comments
Description
N/A
OK
21Alignment Handing over check list
22Comments
N/A
Handing over check list
OK
Confirm driver has been installed and initial
alignment completed and accepted.
13
Confirm suction and discharge nozzles are
installed as per design and alignment is correct
and stress free.
14
Confirm pipe strain checked and corrected.
15
Confirm free rotation and correct direction is
clearly marked.
16
Confirm bearings and seals are clean and free
from damage
17
Confirm coupling hubs are clean damage free and
match marked.
Confirm that after final code alignment with pipe
work is connected, the misalignment tolerance is
maintained after releasing spring pipe supports
.
18
Ensure guards are fitted and in accordance with
area design requirements
19
23CHAPTER 2
1-Types of Alignment
24Parallel misalignment
Vertical
OR
Horizontal
25Angular Misalignment
Vertical
Equipment
OR
Driver
Horizontal
26Correcting of Misalignment
I- Vertical Plane
A- Parallel Misalignment
Equipment
27I- Vertical Plane
B- Angular Misalignment
Equipment
28II- HORIZONTAL Plane
A- Parallel Misalignment
28
29II- HORIZONTAL Plane
A- Parallel Misalignment
29
30II- HORIZONTAL Plane
B- Angular Misalignment
30
3131
3232
332- Dial indicators Types and Functions.
34Dial indicators Types and Functions
Negative direction Stem moves out
positive direction Stem moves in
-10
10
-20
20
30
-30
40
40
-50
50
3510
190
20
180
30
170
40
160
50
150
140
60
130
70
80
120
90
110
100
36CHAPTER 3
1- Preparation on Alignment
37Measure and correct
Pipe strain
Soft foot
Run out
Thermal growth
Mechanical centre
Magnetic centre
38 Pipe strain
Maximum 0.002 in
EQUIPMENT
PLANT LINE
39 Soft foot
Maximum 0.002
One driver leg is not settled on the base
40 Run out
Maximum 0.002
EQUIPMENT SHAFT
41 Thermal growth for hot liquid pumps
1- Apply the alignment procedure for the pump at
ambient Temp. 2- Heat up the pump by opening the
start up bypass for ½ hrs. 3- Put the dial
indicator on the coupling rim and adjust to zero
reading 4- close the bypass 5- Take the dial
indicator reading after 24 hrs. 6- This reading
is the thermal growth 7- Add the thermal growth
reading as a shims under the driver legs
X Thermal growth
Equipment
Driver
42 Thermal growth for Compressors
1- Apply the alignment for the compressor at
ambient Temp. 2- Go to manufacturer catalogue
and read the thermal growth amount. 3- Add the
thermal growth reading as a shims under the
driver legs
After minutes of Starting
Equipment
X Thermal growth
43This design is to avoid any thermal growth
As thermal expansion will be in all directions
Equipment
43
44Electrical motors have no thrust bearings as they
have instead a magnetic center
Driver
44
45Measurement of bar sag.
The attachment that will be used
Piece of Pipe
Bar Sag on 12 O'clock Position
46Piece of Pipe
472-How To Do Alignment
48Driver
Equipment
48
49Driver
Equipment
Driver
Equipment
50VERTICAL READINGS
Parallel actual misalignment
x
51HORIZONTAL READINGS
Parallel actual misalignment
x
If both shafts rotate or one shaft rotates,
the dial indicator reading is the same, and is
equal to double value of the actual
Misalignment amount
521-Reversal Alignment
F
Driver
Equipment
M
53F
M
54PARALELL READINGS
12 Ock
12 Ock
54
6 Ock
6 Ock
55PARALELL READINGS
12 Ock
12 Ock
55
6 Ock
6 Ock
56CHAPTER 4
1-Reversal AlignmentCalculation Method
57(No Transcript)
58VERTICALLY
X
Inboard
MV
FV
FV
F
M
58
59VERTICALLY
Y
Out board
FV
MV
FV
F
M
59
60 D1 4 in D2 8 in D3 16 in
Sag ( 0 )
612-Reversal AlignmentGraphical Method
62Vertically
62
63EXAMPLE
FV 18 mils MV 32 mils
Remove shims
F
M
Add shims
64Horizontally
64
5/3/2006
65EXAMPLE
FH 10 mils MH 20mils
663-Reversal Alignment Software
67Rim and Face Alignment
P Parallel Reading A Angular Reading
Driver
Equipment
68OR
A
P
68
69PARALELL READING
12 Ock
3 Ock
9 Ock.
6 Ock
69
70ANGULAR READING
12 Ock
6 Ock
70
71ANGULAR READING
3 Ock
9 Ock
71
72CHAPTER 5
1-Rim and FaceAlignment Calculation Method
73CALCULATION METHOD
A ANGULAR READING
P PARALLEL READING
74VERTICALLY
X
Inboard pv
AV
D
AV
PV
Outboard
Inboard
D
X
PV
Y
75P
A
0
0
0
0
-14
8
-6
-16
75
76X 4 in Y 12 in D 4
in Sag -1
P
A
0
0
0
0
-14
8
-6
-16
VERTICALLY
HORIZONTALLY
76
772- Rim and Face Alignment Graphical
Method
78Vertically
79EXAMPLE
AV - 16 mils PV - 2 mils
80Horizontally
80
81EXAMPLE
PH - 7 mils AH 8 mils
82Horizontally
If PH 7
833-Rim and Face Alignment Software
84CHAPTER 6
1- Optical Alignment
85Optical Alignment
M
86(No Transcript)
87(No Transcript)
88Transducer
89REFLECTOR
Rotate the side thumb Wheel to raise or lower
the reflector
This lever to lock The reflector position
90REFLECTOR
VERTICAL ADJUSTMENT
91OFF Beam misses detector Red Blinks
quickly Green Is OFF
OFF
END Beam hits non linearized area of
detector Red Green Blinks quickly
Alternatively
END
COORDINATES Beam hits area of detector Red
Green Blinks Slowly
Together
-2 1
921- PREPARING FOR ALIGNMENT PROCEDURE
a- Solid flat foundation
b- Machine mobility ( 2 mm higher screw type
positioning )
c- Soft foot ( Must be checked immediately)
d- Thermal growth
93HORIZONTAL MACHINE ALIGNMENT
1-Transducer to reflector
2-Transducer to coupling center
3-Coupling diameter
4-RPM
5-Transducer to front feet
6- Front feet to rear feet
94DIM
CONFIRM EACH ENTERY WITH ENT
1
2
3
4 RPM
5
6
95DIM
96DIM
97DIM
BEAM DEFLECTOR
98DIM
995-Laser beam adjusting
Rotate the side thumb Wheel to raise or lower
the reflector
This lever to lock The reflector position
100CHAPTER 7
- Case Studies
- For Alignment
- Failure
101A- Bearings Failure
102THRUST BEARING
RADIAL BEARING
ball Bearings
roller Bearings
Tilting pad Bearings
103DRIVE END
NON-DRIVE END
HANGED BEAM IMPELLER
104Thrust Ball Bearings
105(No Transcript)
106(No Transcript)
107(No Transcript)
108Mechanical seal and bearings arrangement
109THRUST PAD BEARING
110THRUSTCOLLAR
111(No Transcript)
112(No Transcript)
113Titan 130 Thrust Bearing
114(No Transcript)
115(No Transcript)
116Radial Tilt-Pad Bearing
117RADIAL TILTING PAD BEARING
118Oil Wedge
Friction Effect
Oil Wedge Effect
Shaft
119Oil Wedge
Oil adhere to the rotating shaft
120RADIAL TILTING PAD BEARING
121B- Pumps Cavitations Failure
122IN PUMPS
123CAVITATION CAN OCCUR in
AND
124What is cavitations phenomenon
It is an action of fluid vapor attack on the
parts of equipment which produce suction
pressure less than vapor pressure of the pumped
fluid.
125This action will cause loss of the
weakest component element of suction parts
material due to bubble explosion on the surface
of suction parts causing cavities .
Vapor bubble explosion on the parts surface
could be 10,000 psi.
126(No Transcript)
127Pump suction parts
128LOST ELEMENTS IN SUCTION PARTS
CARBON STEEL CAST IRON STIANLESS STEEL
BRONZ BRASS
129Cavitations effect on an impeller, indicated by
the cavities appearance of cavitated regions on
the surface
130Damage to the pressure side of the vane from
discharge recirculation
131(No Transcript)
132What is Cavitations Effect
1- CENTRIFUGAL PUMPS
Impeller deterioration
Decrease discharge pressure
Decrease pump flow rate
Increase vibration level
Bearings M/S failure
1332- RECIPROCATING PUMPS
Suction valve deteriorations
Spring Rupture
Decrease discharge pressure
Decrease pump flow rate
Cylinder Head Damage
Piston Damage
134 NPSH
1- NET POSITIVE SUCTION HEAD REQUIRED
YOU CAN GET FROM PUMP MANUAL
2- NET POSITIVE SUCTION HEAD AVAILABLE
YOU CAN CALCULATE FROM PUMP SITE
135What is the parameters affecting
NPSHA
SUCTION PIPE LENGTH
SUCTION PIPE DIAMETER
LIQUID SPECIFIC GRAVITY
INTERNAL SURFACE OF SUCTION PIPE
LIQUID SURFACE ALTITUDE
VAPOR CONTAMINATION
SUCTION PIPE LEAKS
SUCTION PRESSURE
LIQUID TEMPERATURE
LIQUID VISCOCITY
LIQUID VAPOR PRESURE
ATMOSPHERIC PRESSURE
136HOW TO IMPROVE NPSHA
SHORTEN THE SUCTION PIPE LENGTH
INCREASE SUCTION PIPE SIZE
DECREASE SUCTION LIQUID TEMP.
DECREASE SUCTION NEGATIVE ALTITUDE
INCREASE SUCTION POSITIVE ALTITUDE
STOP THE PIPING SUCTION LEAKS
RENEW THE SUCTION PIPE
137NET POSITIVE () SUCTION HEAD
Z liquid surface height ft
PS Pump suction pressure psig
V liquid velocity
ft/sec
Pf Friction Pressure drop psi
Pa Atm. Pressure psi
Vp Vapor pressure psia
h L Suction head loss ft
g 32.2
ft/sec.sec
138EQUATION DIMENTIONS
NPSHA
( ft )
2
V
P sva Vp 2.31
hL
Z
-
2g
Sp.gr
2
2 V
2
ft
ft
sec
2
sec
( ft )
2g
ft
ft
2
2
sec
sec
Lb
3
ft
P
2
ft
( ft )
Sp.g
Lb
2
ft
3
ft
139NPSHA
IS
NOT
OR
1401
General Equation
V
141IF The Suction pressure is known
P sva
Vp 2.31
Psa
Sp.gr
1422
If The Suction pressure is known
NPSHA
143Boiled water
Positive Reading
PS
Z
Z lt hL
CAVITATION OCCURED
144PS
Negative Pressure
NO CAVITATION
PS
145SUCTION NEGATIVE ALTIDUDE NOT MORE THAN 6
METERS
146ATMOSPHERIC PRESSURE
10,033 mt OF WATER
SPACE
SPACE
76 Cm MERCURY
water
ATMS
ATMS
147Pump Eff. 100
PS
VACUUM
PS
10,033 mt OF WATER
PS
ATMS
148CENTRIFUGAL PUMPS LOSSES
H ft
10 20 30 40 50
60
Q g.p.m.
100 200 300 400
500
149PS
PS
6 mt WATER
PS
150VAPOR PRESSURE
1- Heat up a little of water in a pot up
to boiling point 100 C ( valve 1 is
opened)
2- Take off the heating source,
simultaneously close valve 1.
1513- During cooling down, Start to record the P
Gauge relevant to Temp.
152Vapor Pressure
5- Record the Absolute Liquid vapor
pressure.
153Vapor Pressure
The absolute pressure exerted by the equilibrium
vapor of a liquid when confined in a closed
Previously evacuated tank
GPSA 1-7
Liquid vapor
Liquid
T CONSTANT
154( Neglect velocity head (
Solution
8 31 - 12
27 ( ft )
Compare with NPSHR
155( Neglect velocity head (
Solution
8 2 - 2
8 ( ft )
Compare with NPSHR
156Examples
If the liquid level
Z - 12 ft
is 1 ft of liquid
, Friction loss
, Atmospheric pressure is
( Neglect velocity head (
, water sp gr. is
,Vp 3.7 psia
FIND NPSHA
Solution
12.8 ( ft )
Compare with NPSHR
157( Neglect velocity head (
FIND NPSHA
Solution
16 . 46 ( ft )
Compare with NPSHR
158( Neglect velocity head (
FIND NPSHA
Solution
( - 6.6 ) ( ft )
Compare with NPSHR
159Examples
If the liquid is butane and level is
z - 8 ft
System pressure is 60 psia.
Temperature is 90 F
( Neglect velocity head (
Vp 44 psia at 90 F, butane sp.gr is 0.58
FIND NPSHA
Friction loss 12 ft of liquid,
Solution
43.7 ft
Compare with NPSHR
160( Neglect velocity head (
FIND NPSHA
Solution
7.33 ( ft )
Compare with NPSHR