CM M 03 Alignment

8/9/2019 CM M 03 Alignment

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CONSTRUCTION MAINTENANCECONSTRUCTION MAINTENANCE

DEPARTMENTDEPARTMENT

MECHANICAL TECHNICIANMECHANICAL TECHNICIAN

QUALIFICATION MODULEQUALIFICATION MODULE

ALIGNMENT TRAININGALIGNMENT TRAINING

COURSECOURSE

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http://equatenet/default.htm


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INTRODUCTIONINTRODUCTION

With any shaft-to-shaft alignment

it is im!o"tant to fin# the a$is of

"otation of one shaft "elati%e to the

othe" to eliminate the effe&ts of

mo'ntingerrors on the

measurement.

("o!e"ly aligne# moto"s an# !'m!s

)ill last longe" !e"fo"m *ette" an# 'se

less ele&t"i&ity+ Not only )ill yo'

!e"fo"m moto",!'m! alignment in

"e&o"# time *'t yo' )ill also in&"ease

the life of yo'" moto" *ea"ings an#

seals sa%ing yo' tho'san#s of #olla"s

ann'ally in "e#'&e# maintenan&e &osts+ HOME

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O.ECTI/E0O.ECTI/E0

IN THI0 TRAININ1 MODULE THE ATTENDANT WILL LEARN 2

EXIT

Ty!es Of Alignment+

Real &ost of misalignment+

What &a'ses misalignment3

Co'!ling ga!s magneti& &ente"s+

0oft foot+

a" sag t"'e #i"e&tions &o'!ling *a&4lash+

("e-alignment &he&4s+

0t"aight e#ge 5 feele" ga'ge metho#+

Rim 5 Fa&e metho#+

Re%e"se o" #o'*le #ial in#i&ato" metho#+

1"a!hing+

Alignment ti!s+


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MAIN MENUMAIN MENU

Lea"ning

O*6e&ti%es

Data 0heets

Flash Ca"#s

Misalignment

Ty!es

Alignment

Methods


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RADIAL RUNOUTRADIAL RUNOUT

The amo'nt of

e&&ent"i&ity in the

&o'!ling h'*+

0haft "'n o't+

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A7IAL (LA8A7IAL (LA8

The amo'nt of )hi&h a

ma&hine shaft &an mo%e

along its a$is+

Ho) to meas'"e the a$ial!lay3

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1 PUSH

2 ZERO

3 PULL

FACE RUNOUTFACE RUNOUT

The amo'nt of fa&e

s9'a"e ness )ithshaft a$is+

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POWER ON

POWER OFF

MA1NETIC CENTREMA1NETIC CENTRE

Moto" "oto"s )hen

"'n shifts to its

&ent"e !osition this

is &alle# magneti&

&ent"e+

efo"e yo' &o'!le

the moto" "oto" has

to *e &ente"e#+

HOME

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EFFECT0 OF MI0-ALI1NMENTEFFECT0 OF MI0-ALI1NMENT

E$&essi%e ma&hine"y %i*"ation+

E$&essi%e ele&t"i&al !o)e" &ons'm!tion+

("emat'"e *ea"ing fail'"e+

("emat'"e fail'"e of gas4et !a&4ing an# me&hani&al seals+

("emat'"e &o'!ling !a"ts fail'"e+

E$&essi%e ma&hine"y #o)ntime+

E$&essi%e maintenan&e &ost+ : me&hani&al seal;

Lost !"o#'&tion an# !"ofits+

Wa"nings an# sala"y #e#'&tions+

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CAU0E0 OF /IRATIONCAU0E0 OF /IRATIONMisalignment+

Loose tie #o)n *olts+

Loose &o'!ling *olts+

Un*alan&e+

Loose fits of machinery parts.

Machinery runs on over load.

Having cavitations.

And other reasons.

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/IRATION CO0T/IRATION CO0T

/i*"ation is a )aste# ene"gy s!ent in the fo"m of )atts+

/i*"ation sho"tens ma&hine"y &om!onents life+

Ma&hine"y &om!onents e$am!les a"e2 ea"ings seals an# &o'!lings+

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?=>

@=>

== h!

?B= h!

< h!

(lant Ma&hine"y Dist"i*'tion

/IRATION ENER18 CO0T/IRATION ENER18 CO0T

/i*"ation is a )aste# ene"gy

s!ent in the fo"m of )atts+

= / 7 ? am! 7 (F :?; = WATT0+

= , ?=== =+ )+ H"

=+ )+ H" 7


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10 %

40 %

50 %

BEARING FAILURE BARREL

EARIN1 FAILUREEARIN1 FAILURE

Less than ?=> of the ma&hine"y

*ea"ings "ea&h thei" #esign life+

B=> of all ma&hine"y *ea"ing

fail'"e is *e&a'se of

misalignment+

=> of *ea"ing fail'"es is*e&a'se of 'n*alan&e+

?=> *ea"ing fail'"es a"e fo"

othe" "easons+HOME

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B

XA

X = (A+B)/2

X : KE LENG!H"A : SHAF! KE#A

B : $OUPLING HUP KE#A

=> OF THE EARIN1 FAILURE0=> OF THE EARIN1 FAILURE0

DUE TO UN-ALANCE HOW3

Damaged coupling olts.

Damaged coupling !eys.

Damaged coupling hu.

Di"t an# )o"n !a"ts+

Tole"an&e stan#a"#s+

Im!"o!e" "emo%ing an# fi$ing

of &o'!ling h'*s on the shaft+

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?=> OF THE EARIN1 FAILURE0?=> OF THE EARIN1 FAILURE0

?=> of the *ea"ing fail'"es #'e to othe" "easons+

Tie #o)n *olts to"9'e+

E&&ent"i&ity+

a# mo'nting+

Oil seal fail'"e+

Oil #i"ty oil not &hange# fo" long an# im!"o!e" oil g"a#e 'se#+

An# many othe" "easons+

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30%ISALIGNEN!

&IBRA!ION

10 %

O!HER

25 %

ASSEBLERRORS

2' %

OPERA!ION

0EAL FAILURE00EAL FAILURE0

=> of the me&hani&al seal fail'"esa"e #'e to misalignment an#

%i*"ation+

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T8(E0 OF MI0-ALI1NMENT0T8(E0 OF MI0-ALI1NMENT0

Ang'la" misalignment+

PRALLEL

ANGULAR

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A$ial misalignment+ (a"allel misalignment+


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T8(E0 OF MI0-ALI1NMENT0T8(E0 OF MI0-ALI1NMENT0

Ang'la" Misalignment2

: 0ometimes "efe""e# as Kga!J o" Kfa&eJ; is

a&t'ally the #iffe"en&e in the slo!e of one

shaft 's'ally the mo%ea*le ma&hine as

&om!a"e# to slo!e of the shaft of the othe"

ma&hine 's'ally the stationa"y ma&hine+ The

'nits fo" this meas'"ement a"e &om!a"a*le

to the meas'"ement of the slo!e of a "oof

Rise,R'n+ In this &ase the "ise is meas'"e# in

Mils :? Mil =+==?J;+ An# the "'n :#istan&e

along the shaft; is meas'"e# in in&hesthe"efo"e the 'nits of Ang'la" Misalignment

a"e Mils,?J

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CAU0E0 OF MI0-ALI1NMENTCAU0E0 OF MI0-ALI1NMENT

ase !late not in le%el+

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The"mal g"o)th+ Loose tie #o)n *olts+

(i!e st"ain+
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THERMAL 1ROWTHTHERMAL 1ROWTHIs the &hange in the length of a

!a"ti&'la" metal as a "es'lt of the

&hange in tem!e"at'"e of that metal+

Ty!i&ally )hen a metal *a" is heate# it

)ill get longe"+ These &hanges &an *e

%e"y small :=+===BJ; o" they &an *e %e"yla"ge #e!en#ing on the length of the

!ie&e of metal an# its &oeffi&ient of

linea" e$!ansion+ The fo"m'la 'se# fo"

this &al&'lation is often "efe""e# to as

the T $ L $ C fo"m'la+ T "e!"esent the

&hange in the mate"ials tem!e"at'"e in#eg"ees Fah"enheit L "e!"esents the

length in in&hes of the mate"ial an# C

"e!"esents the mate"ials &oeffi&ient of

line" e$!ansion+HOME

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TIE DOWN OLT0TIE DOWN OLT0

When the ma&hine is "emo%e# f"om

the *ase !late ta! the tie #o)n

st'#s+ Re!o"t it if yo' fin# them

loose in the *ase !late+

Tie #o)n *olts sho'l# *e to"9'e

&o""e&tly+

Too tight o" loose *olts might not

se&'"e the ma&hine !"o!e"ly o"

#am! %i*"ation+

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(I(E 0TRAIN(I(E 0TRAIN

While &onne&ting s'&tion an#

#is&ha"ge flanges lea%e the #ial

in#i&ato"s on the ma&hine an# note

the "ea#ings of the !i!e st"ain+

(i!e st"ain sho'l# not effe&t

alignment mo"e than TWO mils+

CAUSES MACHINE FRAME

DISTORTION.

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0OFT FOOT0OFT FOOTIt settles afte" a )hile *e&a'se of the ma&hine )eight+

ase settling &a'ses the ma&hine f"ame to #isto"te#+

0oft foot has to *e &o""e&te# *efo"e yo' !e"fo"m alignment+

UNHAPP A$HINE

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0OFT FOOT0OFT FOOT

Ho) to &he&4 fo" soft foot3

?+ y #ial ga'ge+


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S!EPPE

SHIING

*

ORIGINAL

SHIS

0OFT FOOT0OFT FOOT What is a soft foot3

Ang'la" 0oft Foot is a &on#ition that o&&'"s )hen a ga! 'n#e" a

moto"s foot is Knon-!a"allelJ to the mo'nting *ase+ e&a'se of this

ga! the foot )hen tightene# is fo"&e# to seat itself to )hate%e"

angle allo)s it to ma4e total s'"fa&e &onta&t+ As a "es'lt of this

seating st"esses a"e &"eate# in the moto"s foot that t"ansfe"s

th"o'gh the moto" KlegJ an# into the ho'sing+

?+ y ma&hining+


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0(RIN1 FOOT0(RIN1 FOOT Too many shims 'n#e" the foot of the ma&hine &an &a'se s!"ing

foot+ : shims Ma$+ sho'l# *e 'se#+;

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*

!OO

AN

SHIS


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AR 0A1AR 0A1

Ho) to #ete"mine a *a" sag3

1

2

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ACLA0HACLA0H

One of the !"e&ision alignment 6o*)aste"+

Will a## a*o't =+==


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TI(0TI(0 (la&e the thin shim *et)een the t)o thi&4e" ones+

Use mi&"omete" to meas'"e ea&h shim thi&4ness to a%oi# e""o"s #'e to

t)o thin shims sti&4ing togethe"+

Ne%e" hamme" on ma&hine feet+ : Use 6a&4 *olts;

Ma4e s'"e the enti"e a"ea 'n#e" the ma&hine feet is &lean this in&l'#es

"emo%al of !aint o" othe" mate"ials that &an gi%e e""o" in the "ea#ings+

Use #ial in#i&ato"s )hen mo%ing ho"iontally+

("e%ent &'!!e# )ashe"s+

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0TRAI1HT ED1E 5 FEELER 1AUA1E0TRAI1HT ED1E 5 FEELER 1AUA1EMETHOD0METHOD0

AD/ANTA1E0

As an initial "o'gh

alignment this metho# is

fast+

1ene"ally in%ol%es t"ail 5

e""o" )ay+

Ineffi&ient+ : Time Waste#;

Misalignment "ea#ings a"e

not a&&'"ate+

DI0-AD/ANTA1E0

ERROR 0CORE0

0haft , &o'!ling "'n o't+

(oo" shaft , &o'!ling s'"fa&e+

Ina&&'"ate meas'"ement te&hni9'es+

In&o""e&t &lo&4 !osition+

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RIM 5 FACERIM 5 FACEAD/ANTA1E0

May *e 'se# )hen only

one shaft &an *e "otate#+

("e&ision alignment 's

a&hie%a*le+

1"a!hi&al an# &al&'lation

is !ossi*le+

Re9'i"es #is-assem*ly of

the &o'!lings+

Often in%ol%es t"ial an#

e""o"+

Time &ons'ming+

DI0-AD/ANTA1E0

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RE/ER0E DIAL INDICATORRE/ER0E DIAL INDICATORAD/ANTA1E0

("e&ision alignment is

"ea#ily a%aila*le+

Dete"mination of "e9'i"e#

mo%es is effi&ient+

Re9'i"e ?= #eg"ee"otation of shaft+

No nee# to )o""y a*o't

a$ial !lay

Mo"e #iffi&'lt to inte"!"et

#i"e&tions of mo%es f"om

in#i&ato"s "ea#ings+

a" sag if 'se# )ith long

e$tension+

DI0-AD/ANTA1E0

ERROR 0OURCE0

In#i&ato" *a" sag+

Mis"ea#ing in#i&ato"+

Co'!ling *a&4lash+

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LA0ER ALI1NMENTLA0ER ALI1NMENT

AD/ANTA1E0

Q'i&4 #ete"mination of"e9'i"e# mo%es+

Long s!ans *et)een

&o'!lings is not a

!"o*lem+

1i%es %e"ti&al an#ho"iontal mo%es at on&e+

Costly+

Cant *e 'se# )hen the

s'n light is too *"ight+

DI0-AD/ANTA1E0

ERROR 0OURCE0

Lase" fi$t'"e sag , t)ist+ : no sag o" t)ist in fi$t'"e;

Am*ient %i*"ation an# am*ient tem!e"at'"e+Co'!ling *a&4lash+

Lase" *eam #isto"tion #'e to st"eam o" #i"ty !"ism , lens+

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Afte" ?= yea"s of lase" shaft alignment it is no) an esta*lishe#

fa&t that lase"s a"e sim!ly faste" than in#i&ato" *ase# metho#s+

The *igge" the moto" the mo"e time sa%e# #'"ing alignments+ It)as tol# *y one &'stome" that they "e#'&e# the alignment time on

one moto" f"om < #ays to ho'"s This time sa%ing &an *e

es!e&ially hel!f'l on &"iti&al ma&hine"y )he"e #o)ntime is %e"y

&ostly+


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TI(0 ON HOW TO U0E MEA0URIN1TI(0 ON HOW TO U0E MEA0URIN1

TOOL0TOOL0FEELER 1UA1E Do not fo"&e the ga'ge in ga!s+

Use &om*ination of ga'ges that fills the ga! )ith only

slight "esistan&e+

)hen se%e"al ga'ges a"e &om*ine# to fill a ga! it is *est

to &he&4 the o%e"all thi&4ness )ith a mi&"omete"+

DIAL INDICATOR

Mo'nt "im #ials so that !l'nge" is t"'ly !e"!en#i&'la" to the shaft

&ent"e line+

Che&4 "im "ea#ings fo" mathemati&al %ali#ity+

Mo'nt the fa&e #ial so that !l'nge" is t"'ly !a"allel to the shaft

&ent"e+

Che&4 "ea#ings fo" "e!eata*ility+

Eliminate *a&4lash effe&t on "ea#ings+

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(RE-ALI1NMENT CHEC0(RE-ALI1NMENT CHEC0Dete"mine alignment metho# to *e 'se#+

("e!a"e the ne&essa"y tools "e9'i"e# fo" the alignment 6o*+

If !ossi*le &he&4 yo'" magneti& &ent"e an# ma4e yo'" ma"4ings+

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O 0 OIM(ORTANT DIMEN0ION


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AB

$

E

# X Z

A: IS!AN$E BE!#EEN IAL INI$A!ORS PLANS"

B: IS!" BE!#EEN !ARGE! INI$" 8 SIGH! A$HIN INBOAR FEE!"

$: IS!" BE!#EEN !ARGE! INI$" 8 SIGH! A$H" OU! BOUR FEE!"

: IS!" BE!#EEN !ARGE! INI$" 8 !ARGE! A$H" INBOAR FEE!"

E: IS!" BE!#EEN !ARGE! INI$" 8 !ARGE! A$H" OU! BOAR FEE!"

#9X99Z : !HERAL GRO#!H IN EA$H SEPARA!E FEE!"

!AGE! SIGH!

IM(ORTANT DIMEN0IONIM(ORTANT DIMEN0ION

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H-; 6.;: 1 S

: A$H" FEE!

: !ARGE! IAL"

INI$A!OR"

: SIGH! IAL "

II$A!OR"

1'"524"5

53'"5

30"5

"""O NO! FORGE!

!O ESURE BAR

SAG"

E7AM(LE ?+?E7AM(LE ?+?

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$AL $AL

$AL :!ARGE! $OL

"" ALIGNEN! LINE"

$AL :SIGH! $OL"" ALIGNEN! LINE"

!IR: !O!AL IAL ""

INI$A!OR """ """"

REAING"

H-; 6.;: 1 S


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&-.; 6.;: 1 S


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&-.; 6.;: 1 S


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(RO1RAM OUT(UT(RO1RAM OUT(UT

8OUR IN(UT0 ARE

A ?@+B==


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THERMAL 1ROWTH ?+?THERMAL 1ROWTH ?+?Fo" the"mal g"o)th )e nee# to 4no) the follo)ing2

Off set %al'es of $ ) y 5 +Final #esi"e# "ea#ing on the #ial in#i&ato"s+

!HERAL GO#!H

OFFSE! : ($HANGE +/@)

+ 10 + '"5

@ 10 @ '"5

!HERAL GO#!H

OFFSE! : ($HANGE +/@)

+ 3 + 5

@ 3 @ 5

# X Z

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THERMAL 1ROWTH ?


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THERMAL 1ROWTH ?+


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THERMAL 1ROWTH ?+THERMAL 1ROWTH ?+

+ 1SAG

+ 4"5

($HANGE +/@)

Times 2

@

C

!IR

+ 1?"5SAG

+5"5

Times 2

!IR+ 11

Measure the distance

and direction (+) or(-)

FROthe coldalignment line !Othe

sight cold alignment

line.

FN!" #E$RE# TOT!"

N#%!TOR RE!#N&$

FOR %O"# !"&NMENT

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DRAW THE 1RA(H ? DRAW THE 1RA(H ?


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DRAW THE 1RA(H ?+DRAW THE 1RA(H ?+

A A

E

E +5

+

A A

B

B

HAL

$AL$AL

HAL

$

%AL

A: !HERAL OFFSE!S

EASURE IN FEE!

PLANES"B: FINAL ESIRE

INI$A!OR REAINGS"

(REA ON !HE BA$K OF

!HIS PAGE)

$: !ARGE! INI$A!OR

ISALIGNEN!

PLO!!E FRO !ARGE!

$AL"

: SIGH! INI$A!ORISALIGNEN!

PLO!!E FRO !ARGE!

$AL"

E: $ORRE$!IONS

ESURE IN PLANES OF

FEE!S"

$AL:!ARGE! $OL

ALIGNEN! LINE"

HAL :!ARGE! HO! ALIGNEN! LINE"

$AL :SIGH! $OL

ALIGNEN! LINE"

HAL :SIGH! HO!

ALIGNEN! LINE"

AL :ISALIGNEN!

LINE"H-; 6.;: 1 S


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(RO1RAME OUT(UT(RO1RAME OUT(UT

8OUR IN(UT0 AREA ?@+B==


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HORIPONTAL8HORIPONTAL8

!IR 0"0

1/2 !IR

+/@ PLO!

!IR 0"0

1/2 !IR PLO!

E%e"ything is the same *'t igno"e the *a" sag+

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HORIPONTAL8HORIPONTAL8

+ 2"5

:CHAN1E ,-;

Times


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(RACTICE(RACTICE

1"a!h (a!e"HOME

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CHAIN ALI1NMENTCHAIN ALI1NMENT

0!"o&4ets sho'l# *e t"'e

an# %e"ti&al+

oth s!"o&4ets sho'l#

ha%e the same !lan+ :Co"#

sho'l# to'&h all !oints; 0la&4 ? to < > &ent"e to

&ent"e #istan&e+

+

+

++

+

++

+

+

+

+

+

+

E7CE00I/E 0LAC

NORMAL 0LAC

WEAR (OINT

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FOR 8OUR INFORMATIONFOR 8OUR INFORMATION

A st'#y &on#'&te# *y one of the )o"l#s la"gest se"%i&e &om!anies in#i&ate#that less than @> of the "otating e9'i!ment )e"e aligne# to )ithin the

tole"an&e gi%en *y the ma&hine man'fa&t'"es+

We sho'l# t"y to in&l'#e EQUATE0 "otating e9'i!ments in this @>+

EQUATE nee#s yo' to "efe" to all the "otating e9'i!ment man'als s!e&ially the

&"iti&al e9'i!ments *efo"e yo' !e"fo"m any alignment 6o* on any "otating

e9'i!ment+

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ADDITIONAL INFORMATIONADDITIONAL INFORMATION


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ADDITIONAL INFORMATIONADDITIONAL INFORMATION

Nee# mo"e info"mation3Nee# mo"e info"mation3 As4 yo'" Colleag'es Team lea#e" Enginee" o" MAC+As4 yo'" Colleag'es Team lea#e" Enginee" o" MAC+

Rea# mo"e info"mation *oo4s on alignment fo" mo"e 4no)le#ge an#Rea# mo"e info"mation *oo4s on alignment fo" mo"e 4no)le#ge an#

s4ills+s4ills+

Than4 yo'

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Flash Ca"#sFlash Ca"#s

#.0haft alignments means a$is of "otation of one shaft "elate# to the othe"

shaft to eliminate the effe&ts of mo'nting e""o"s on the meas'"ement+

TRUETRUE

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FAL0EFAL0E

The Ans)e" is T"'e


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("o!e"ly aligne# moto"s an# !'m!s )ill

last longe" !e"fo"m *ette" an# 'se lessele&t"i&ity+ Not only )ill yo' !e"fo"m

moto",!'m! alignment in "e&o"# time *'t

yo' )ill also in&"ease the life of yo'"

moto" *ea"ings an# seals sa%ing yo'

tho'san#s of #olla"s ann'ally in "e#'&e#

maintenan&e &osts+


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+ What #o yo' 'n#e"stan# *y Ra#ial R'n O't3 : Cli&4 the "ight ans)e"s;

The amo'nt of e&&ent"i&ity in the &o'!ling h'*+

The amo'nt of )hi&h a ma&hine shaft &an mo%e along its a$is+

The amo'nt of fa&e s9'a"e ness )ith shaft a$is+

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0ight Ans1er0ight Ans1er

C


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+The ty!es of misalignment a"e2

a; A$ial misalignment+

*; (a"allel misalignment+

&; Ang'la" misalignment

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TRUETRUE FAL0EFAL0E

The Ans)e" is T"'e


Fl h C #


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B+ 0oft foot &an *e igno"e# )hile !e"fo"ming an alignment *e&a'se soft

foot has no im!o"tan&e )hile &a""ying o't an alignment+

0oft foot ha%e to *e &o""e&te# *efo"e

yo' sta"t any alignment on anye9'i!ment+

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TRUETRUE FAL0EFAL0E



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Fl h C #Fl h C #


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@+ What a"e the #iffe"ent metho#s of alignment3

:Cli&4 the "ight ans)e"s;

0t"aight e#ge an# feele" ga'ge , ta!e" ga'ge+

Ro!e an# )i"e+

Rim an# Fa&e+

Using o'tsi#e 5 insi#e &ali!e"+

Re%e"se #ial in#i&ato"+

Lase"+

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Fl h C #Fl h C #


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; Thermal gro1th is the change in the length of a particular metal as a

result of the change in temperature of that metal. Typically 1hen a

metal ar is heated it 1ill get longer.

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The Ans)e" is T"'e


Fl h C #Fl h C #


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; a" sag &an *e 'n#e"estimate# an# an a!!"o$imate "ea#ing &an *e

a##e# to yo'" "ea#ing )hile !e"fo"ming alignment+

FAL0EFAL0ETRUETRUE

Ne%e" 'n#e" estimate the *a" sag+

Al)ays %e"ify *y "e!eating the &he&4s s!e&ially )hen meas'"ing the *a" sag+Ne%e" estimate the *a" sag+ Al)ays #o a !"a&ti&al &he&4 to fin# the e$a&t *a"

sag "ea#ing+

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?=; elt tensioning sho'l# *e e9'al too !e" in&h )hen meas'"e#

f"om the &ent"e to &ent"e of t)o !'lleys+

?,


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??; What is the #iffe"en&e *et)een 0oft Foot an# Ang'la" 0oft Foot3

The fi"st ste! #'"ing an alignment is to &he&4 the moto"s feet fo" ga!s+Ea&h foot is &he&4e# a*o%e an# *elo) the shim !a&4 )ith feele" gages to

#ete"mine if the ga! *et)een the foot an# *ase is !a"allel+A !a"allel ga!

in#i&ates "eg'la" 0oft Foot+ A non-!a"allel i""eg'la" ga! means Ang'la"

0oft Foot is !"esent+

TRUETRUE FAL0EFAL0E

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The Ans)e" is T"'e


Date post:	01-Jun-2018
Category:	Documents
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CM M 03 Alignment

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