• Explanation of Offset and angularity

• Alignment Preparation
• Thermal Expansions
• Alignment Methods
• Comparison of Alignment Methods
• Some Laser Alignment Applications

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Explanation of offset and Angularity Cont.

Stationary

Machine 12:00

Elevation view 9:00

3:00

6:00

Stationary

Machine

Plane view

Angularity
Is defined by where the coupling gap I open

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 Explanation of Vertical Angularity Cont.
Positive Vertical Angularity Negative Vertical Angularity

Stationary Stationary
Machine Machine

Offset Offset
Offset Offset Offset
Offset
Stationary Stationary

Machine Machine

Coupling open at 12:00 Coupling open at 6:00

Angularity
Is defined by where the coupling gap is open.
The angle that one shaft centerline makes in relation to the other shaft centerline.
This is expressed as a “SLOPE” of so many thousandths of Inch/Inch, rather than
an angle of so many degrees.
There are Vertical & Horizontal Angularity.

Open at 12:00 is Positive Vertical Angularity (VA).

Open at 6:00 is Negative Vertical Angularity (VA).

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Explanation of Horizontal Angularity Cont.

Positive Horizontal Angularity Negative Horizontal Angularity

M
MTB Stationary MTBM
Stationary
Machine Machine

Offset Offset
Offset Offset Offset
Offset
Stationary Stationary

Machine Machine

Coupling open at 3:00 Coupling open at 9:00

Angularity
Is defined by where the coupling gap is open.
Open at 3:00 is Positive Horizontal Angularity (HA).
Open at 9:00 is Negative Horizontal Angularity (HA).

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 Explanation of Offset
Positive Vertical Offset Positive Horizontal Offset

MTBM
Stationary Stationary MTBM
Machine Machine

Offset Offset

Stationary Stationary

Machine Machine
12:00

12:00
9:00
9:00

3:00
6:00 3:00
6:00
MTBM is high in Vertical MTBM toward 3:00

Offset
The distance (in thousandths of Inch) between two shaft centerlines.
This must be determined in both the Vertical & Horizontal Planes

Positive Offset are when the MTBM is high (Vertical) or toward 3:00
(Horizontal) compared to STAT

Negative Offset are when the MTBM is low (vertical) or toward 9:00
(Horizontal) compared to STAT

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 Explanation of Offset Cont.

Negative Vertical Offset Negative Horizontal Offset

MTBM
Stationary MTBM Stationary
Machine Machine

Offset
Offset
Stationary
Stationary
Machine
Machine
12:00 12:00
9:00
9:00

3:00 3:00
6:00 6:00

MTBM is Low in Vertical MTBM toward 9:00

Offset
The distance (in thousandths of Inch) between two shaft centerlines.
This must be determined in both the Vertical & Horizontal Planes

Positive Offset are when the MTBM is high (Vertical) or toward 3:00
(Horizontal) compared to STAT

Negative Offset are whenthe MTBM is low (vertical) or toward 9:00

(Horizontal) compared to STAT

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 Alignment Preparation
Soft-foot Check
Checking by Dial indicator

A soft-foot check is recommend prior to any alignment.

Previous shimming or a twisted machine bed may cause the machine to rest
unevenly on the feet (soft-foot).

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 Alignment Preparation Cont.

Soft-foot Check
Checking by Laser heads

A soft-foot check is recommend prior to any alignment.

Previous shimming or a twisted machine bed may cause the machine to rest
unevenly on the feet (soft-foot).

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 Alignment Preparation Cont.

Types of Soft-foot

There are two types of soft foot. Parallel soft foot means that foundation and
machine feet are parallel to one another, which allows correction simply by
adding or removing the correct thickness of shims. Angular soft foot is caused by
foundation and machine feet forming an angle with one another, so ordinary
shims will not solve the problem (a characteristic trait of angular soft foot).
Possible solutions include dismounting the machine so that the feet may be
ground down suitably, or using tapered shims to fill the angular space between
feet and foundation.
As a rough guide and in the absence of any manufacturers or on site tolerances,
soft foot should not exceed +/- 0.002" or 0.05 mm at any foot.

٩
 Alignment Preparation Cont.

Sag Measurement

To measure sag, mount the entire measurement fixture (brackets, bars and
indicators) on a piece of straight pipe. Adjust the fixture until the brackets are the
same distance apart as they will be when mounted on the actual machinery.
Likewise, position the indicators as near as possible to the way they will be set on
the machinery. With the indicators at 12:00, zero the dials. Rotate the pipe until
the indicators are at 6:00. Read and record the dial indicators (the rim indicator
will be a negative value, the face indicator may be positive or negative, but
should be close to zero).

١٠
 Alignment Preparation Cont.

Machine Mobility

١١
 Thermal Expansion
Intentional misalignment for cold machine

Example:
Example:
Height
Heightfrom
fromfoundation
foundationtotoshaft:
shaft:1.0
1.0mm
mm
Temperature
Temperaturewhen
whenaligned
aligned +20
+20CC
Operating
Operatingtemperature
temperature +50
+50CC

Thermal
Thermal expansion
expansion=1.0x(50-20)x0.01
=1.0x(50-20)x0.01
==1.0x
1.0x30
30xx0.01
0.01 Proper alignment at operating temperature
==0.3 mm
0.3 mm

ΔL = L(α)(ΔT)
Where
ΔL = thermal expansion
L = height centerline to base of machine
α = coefficient of thermal expansion of material
ΔT =change in temperature from ambient

The influence of different thermal expansion factors for SM** and MTBM* can
be quite significant when measuring.
If the case of an electric motor the thermal expansion is approximately 0.01mm
(0.000394 inch) per meter(40 inch) for every degree Celsius increase in
temperature. For every degree Fahrenheit it is 0.00022 inch.
There are no problem when SM has the same thermal characteristics as MTBM.
In other cases, an attempt should be made to align the machines before they cool
off or compensate for difference.
For example, if SM increases 0.25 mm (0.01 inch) in height as a result of the
heat, the amount of shims required for MTBM must be increased by
0.25mm(0.01 inch) (under all feet).
The manufacture normally supplies information on a machine thermal
characteristics. Check the following when estimating thermal expansion.
- Working temperature of both machine.
- Coefficients of thermal expansion of both machines
- The effects of ambient external sources of heat, cooling systems etc. , .

*MTBM : Machine To Be Move

**SM : Stationary Machine

١٢
 Alignment Methods

• Precision Ruler
• Face & Rim
• Reverse Indicator
• Laser

The alignment method depends on the operating speed and how much
accuracy it is required for a certain machine. The higher speed, the more
accuracy is needed.

Alignment Methods Accuracy

Precision ruler Max. 1/10 mm (4 mils)
Face & Rim Max 1/100 mm (0.4 mils)
Reverse indicator Max 1/100 mm (0.4 mils)
Laser Max. 1/1000 mm (0.04 mils)

١٣
 Alignment Methods Cont.

Precision Ruler

١٤
 Alignment Methods Cont.
The Face & Rim Method
Face Readings obtained as the shafts are rotated and the centerline of
the dial indicator stem is set parallel to the shaft centerline.

Readings obtained as the shafts are rotated and the centreline of the dial
indicator stem is set parallel to the shaft centreline.
Rim & Face Indicator Alignment
The measuring device for this type of alignment is a dial indicator. The dial hand
indicates, or points, to increments marked on the dial face. As the foot is pushed
into the body, the dial hand rotates clockwise. The number of indicator marks that
the hand moves is equal to the distance that the foot was pushed into the body.
When the foot travels out from the body the dial hand similarly indicates the
travel distance. By custom and construction the dial count is positive when the
foot travels in and negative travelling out.
Mounting
Rim and Face alignment takes its name from the positions of the indicator feet
during measurements. A traditional indicator set up is shown above.
Once mounted, the two shafts are rotated together and the dials are read at 12:00,
3:00, 6:00 and 9:00.

١٥
 Alignment Methods Cont.
The Face & Rim Method
Rim Readings obtained as the shafts are rotated and the centerline of the
dial indicator stem is set to 90 degree angle to the shaft centerline.

Readings before shafts are rotated 0 0

Readings after shafts have been rotated 180 0 +12

Readings obtained as the shafts are rotated and the centreline of the dial
indicator stem is set parallel to the shaft centreline.
Rim & Face Indicator Alignment
The measuring device for this type of alignment is a dial indicator. The dial hand
indicates, or points, to increments marked on the dial face. As the foot is pushed
into the body, the dial hand rotates clockwise. The number of indicator marks that
the hand moves is equal to the distance that the foot was pushed into the body.
When the foot travels out from the body the dial hand similarly indicates the
travel distance. By custom and construction the dial count is positive when the
foot travels in and negative travelling out.
Mounting
Rim and Face alignment takes its name from the positions of the indicator feet
during measurements. A traditional indicator set up is shown above.
Once mounted, the two shafts are rotated together and the dials are read at 12:00,
3:00, 6:00 and 9:00.

١٦
 Alignment Methods Cont.
The Face & Rim Method
Face Readings obtained as the shafts are rotated and the centerline of
the dial indicator stem is set parallel to the shaft centerline.
Rim Readings obtained as the shafts are rotated and the centerline of the
dial indicator stem is set to 90 degree angle to the shaft centerline.

Readings obtained as the shafts are rotated and the centreline of the dial
indicator stem is set parallel to the shaft centreline.
Rim & Face Indicator Alignment
The measuring device for this type of alignment is a dial indicator. The dial hand
indicates, or points, to increments marked on the dial face. As the foot is pushed
into the body, the dial hand rotates clockwise. The number of indicator marks that
the hand moves is equal to the distance that the foot was pushed into the body.
When the foot travels out from the body the dial hand similarly indicates the
travel distance. By custom and construction the dial count is positive when the
foot travels in and negative travelling out.
Mounting
Rim and Face alignment takes its name from the positions of the indicator feet
during measurements. A traditional indicator set up is shown above.
Once mounted, the two shafts are rotated together and the dials are read at 12:00,
3:00, 6:00 and 9:00.

١٧
 Calculation for Face & Rim
A raise
B or
C left

Driver Driven
H

Machine Machine
F lower
Y
or
F2 F1 D F3 F4
right
E

Required movement Required movement

for Driver Machine for Driven Machine
F [(D)− (C )] + (Y )
F 1=
FB − (Y ) F 3=
H2− F2
2 2
H −F
F [(E )− (C )] + (Y )
F 2=
FA − (Y ) F 4=
H2− F2
2 2
H −F

Mathematical solution when using the face and rim peripheral method.
Positive (+) values for the inboard (F1or F3) and outboard (F2 or F4) calculation
indicate that the unit has to be raised (i.e., shims added) or moved to the left (i.e.,
lateral movement).
Negative (-) values for the inboard (F1or F3) and outboard (F2 or F4) calculation
indicate that the unit has to be lowered or moved to the right.

١٨
 The Reverse Indicator Reading
This method requires the taking of two (2) Rim
readings; one set at the M.T.B.S and one set at
STATIONRY MACHINE.

This method requires the taking of two (2) Rim readings; one set at the
M.T.B.S and one set at STATIONRY MACHINE.

١٩
 Calculation for Reverse indicator
A raise
B or
C left

Driver Driven

Machine Machine

X Y lower
or
F2 F1 D F3 F4
right
E

Required movement Required movement

for Driver Machine for Driven Machine
B[(X )+ (Y )] − (Y ) F 3=
D[(Y )+ (X )] − (X )
F 1=
C C
A[(X )+ (Y )] − (Y ) E [(Y )+ (X )] − (X )
F 2= F 4=
C C

Mathematical solution when using the reverse indicator method.

Positive (+) values for the inboard (F1or F3) and outboard (F2 or F4) calculation
indicate that the unit has to be raised (i.e., shims added) or moved to the left (i.e.,
lateral movement).
Negative (-) values for the inboard (F1or F3) and outboard (F2 or F4) calculation
indicate that the unit has to be lowered or moved to the right.

٢٠
 Disadvantage of mechanical alignment system

Sagging indicator brackets

Sticking / Jumping dial Hands

Lower resolution=rounding losses

Reading errors: +\- sign error

Parallax error &mirror image

Play in mechanical linkages

Tilted dial indicator=offset error

Axial shaft play = gap error

Until the advent of laser-based alignment Systems, dial indicators were the only
systems capable of yielding accurate alignment results. However, due to their
mechanical construction, they are susceptible to a number of factors which can
compromise accuracy:
Indicator bracket sag: should always be measured before actual alignment
readings are taken - no matter how solid the bracket appears!
Internal frictionihysteresis: sometimes the gauge must be tapped in order for
the indicator needle to settle on its final value (which may still not be the correct
one).
1/100 mm resolution: up to 0.005 mm rounding error may occur with each
reading - for a total of up to 0.04 mm error in values used for result calculations.
This may easily be compounded several times by the time coupling or machine
foot results are obtained.
Reading errors: simple human errors that occur
all too often when dials must be read under cramped, poorly-lit conditions and
severe time constraints. These are often compounded by having to read dials
upside down or front-to-back (using a mirror) at the various shaft rotation
positions required for alignment measurement.
Play in mechanical linkages: slight amounts may not be noticed, yet produce
large errors in results.
Tilted dial indicator: the gauge may not be mounted perpendicular to the
measurement surface so that part of the displacement reading is lost.
Axial shaft play: can affect face readings taken to measure angularity unless two
axially-mounted gauges are used.
These consideration increase the effort and risk of error with dial indicator
measurements. ٢١
Disadvantage of mechanical alignment system

Sagging indicator brackets

Sticking / Jumping dial Hands

Lower resolution=rounding losses

Reading errors: +\- sign error

Parallax error &mirror image

Play in mechanical linkages

Tilted dial indicator=offset error

Axial shaft play = gap error

٢٢
 Laser Alignment

Laser Optical measuring systems have demonstrated significant benefits

for measuring the alignment of rotating shafts.
In this type of system, a semiconductor laser diode is used to generate a
beam of light. The emitted light beam bounces off an optical reflector and
returns to a photo position detector. The exact point where the returned
beam hits the detector will change as the reflector moves. Further more,
the amount of movement in the return beam is exactly proportional to the
movement in the reflector.

٢٣
 Laser Alignment Cont.

• Horizontal Alignment.

٢٤
Laser Alignment Calculation

٢٥
 Horizontal Laser Alignment Procedures

1- Measure with the measuring tape and enter the distance.

2-Choose program 1 and press enter on the display unit

٢٦
 Comparison of Alignment Methods

The straightedge has been (and continues to be) used quite often for alignment.
However, since the resolution of the human eye is limited to 1/10 mm, alignment
accuracy is correspondingly limited.
The corrective values for machine feet are usually estimated according to the
experience of the alignment millwright, who must know the particular machine
involved quite well.
The result: repeated trial alignments are necessary until the machine is more or
less aligned, and even then, the accuracy of results usually leaves much to be
desired.
Alignment using dial gauges represents a considerable advancement over the
straightedge, as measuring accuracy of 1/100 mm, or ten times that of
straightedges may be obtained - provided that the operator has the necessary
training, experience and diligence to mount the hardware and carry out the
procedures properly. In practice, however, alignment with dial indicators ends up
being no more accurate than with straightedges 90% of the time. Calculations
tend to be complicated, and so more often that not, engineers use the dial
readings for trial-and-error adjustment until they read zero at all measurement
positions ignoring bracket sag and a host of other sources of error.
Laser alignment systems as shown in column 3 offer high accuracy 1/1000 mm
have no mechanical fixtures to sag - offer results with no interpretation or
calculations required and repeatable readings across a wide variety of operator
skills.

٢٧
Laser Alignment application

Installation In-Service

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٣٠
End

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