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Misalignment | Power-MI

Aug 21, 2023 2:32 PM

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Low frequency fault diagnosis

Misalignment
By Alfonso Fernandez

Introduction to maintenance

Vibration analysis fundamentals

Vibration sensors and measurement devices

Vibration standards

Imbalance and phase measurement

Low frequency fault diagnosis

Eccentricity

Bent shaft

Misalignment

Looseness

Beating

Plain bearings

Gears
Rolling element bearings

AC induction motors

Resonance

Misalignment is one of the most frequent vibration problems in rotating machinery

and is due to the difficulty of the alignment of two rotors with their respective
supports. Misalignment can happen due to very different causes such as: excessive
reliance on the use of elastic couplings and self-aligning bearings, machine
deformation during operation that leads to displacements of the driving or driven
system, etc. Misalignment will produce very high levels of vibration in the vicinity of
the coupling that can precipitate bearing degradation, coupling blocks wear, bolt
breakage, driver overheating due to an increase in the electrical power consumption,
etc., so it is recommended to correct it before it causes additional considerable
damage that can lead to a machine stop.

Offset misalignment can be measured using dial indicators and corrected with shims
under the feet of the machine's free system
Learn(usually
Signthe motor). AtEnglish
present, there are
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available very accurate pieces of equipment for the measurement and correction of
misalignment, based on brackets to support the dial indicators and even laser
systems. These systems rely on instruments for automatic
Power-MI in it measurement, calculation
of applicable corrections and on-screen display of tolerances and correction offsets.
IN THIS PAGE:
Misalignment occurs when there is little accuracy in the alignment
free between pairs of
Introduction
components, such as coupling elements, bearings, shafts and pulleys. Misalignment
Types of
usually manifests with strong vibration in the axial and radial directions. Axial
misalignment
readings can present the first harmonics of the rotating speed, 1x, 2x and 3x RPM.
RadialAngular
readings normally exhibit activity at 1x and 2x RPM. Low amplitude at the third
misalignment
harmonic frequency and at higher harmonics. However, in some machines the
Offset orvibration due to misalignment occurs at 1xRPM and may be mistaken
predominant
parallel
with unbalance. In these cases it is recommended to perform a phase analysis that
misalignment
will allow to distinguish between problems of unbalance and misalignment. On the
other Bearing
hand, the time waveform is characterized by a repetitive pattern with no
impacts in acceleration.
misalignment
Misaligned
A phase analysis allows us to confirm the diagnosis of misalignment and is
pulleys
characterized by an important phase difference between the bearings closer to the
coupling in the same measurement directions. Another symthom of misalignment is
that the phase difference between horizontal readings is not similar to the phase
difference between vertical readings.

Types of misalignment
There are two types of misalignment, angular misalignment and offset or parallel
misalignment that are described below. In most cases real world misalignment is a
combination of both.

Angular misalignment
There is angular misalignment when the center lines of two shafts are crossed at an
angle. The presence of strong axial vibration at 1x RPM characterizes this type of
misalignment, which may be accompanied by harmonics of the shaft rotating speed
with low amplitudes.

Symptoms:

Strong axial vibration at 1x RPM possibly with 2x and 3x harmonics.

The 2x RPM harmonic in the axial direction can reach a value equal to or even
higher than 1x.

Vibration in the radial direction, probably of smaller amplitude than in the axial
direction, in 1x, 2x and 3x.

The axial phase measurements on both sides of the coupling are 180° out of
phase.
Figure 6.4: Angular misalignment

Offset or parallel misalignment

Two shafts suffer parallel misalignment when they are parallel and at a certain
distance apart. Misalignment can be vertical or horizontal and manifests in the
spectrum with a strong radial vibration at 1x and 2x RPM of the shaft, being able to
present higher harmonics of less amplitude.

Symptoms:

Strong radial vibration in 1x RPM with 2x and 3x harmonics.

The 2x RPM harmonic in the radial direction can reach a value equal to or even
greater than 1x.

The radial phase measurements on both sides of the coupling are 180° out of
phase.
Figure 6.5: Offset or parallel misalignment

Bearing misalignment
Regardless of whether there is good alignment at the coupling, there may be
misalignment between the shaft and the bearing. Misalignment may be caused by a
distortion in the machine or improper mounting. If one foot of the machine is not in
the same plane as the others or if the base plate is not flat, the tightening of the
anchoring bolts will cause a deformation and consequently a misalignment. Another
example of bearing misalignment occurs on large fans where the bearing housings
are mounted on the metal structure of the fan. If the metal structure does not have
sufficient rigidity, it will deform under load conditions and cause misalignment.
Generally, the greater deformation is usually produced at the bearing near the
impeller, causing axial misalignment.

Misaligned ball or cylindrical roller bearings are characterized by axial vibration

regardless of the balancing status. Vibration can appear at 1x, 2x, 3x RPM or at the
number of bearing balls or rollers multiplied by the rotating speed.

Anti-friction bearing misalignment produces radial and axial vibration, usually at 1x

and 2x RPM of the rotating speed. Bearing misalignment is often accompanied by
rotor unbalance, so that a balancing of the rotor will reduce radial and axial vibration.

Symptoms:

Strong axial vibration at 1x RPM possibly with harmonics at 2x and 3x.

 The 2x RPM harmonic in the axial direction can reach a value equal to or even
greater than 1x.

The axial phase readings at the bottom, left, top and right of the bearing are 90°
out of phase.

Figure 6.6: Bearing misalignment

Misaligned pulleys
Two pulleys are considered misaligned when they are not in the same plane. This
problem produces high axial vibration at 1x RPM of the driver or the driven system,
although generally the driven. A good measurement of the vibration amplitudes is
heavily influenced by the location where the data is acquired. The belt pass frequency
and its harmonics are also present in the vibration signature. Keep in mind that belt
frequencies also tend to appear when there is wear on them, so it is sometimes
convenient to check their status. To solve the problem, the pulleys must be aligned
both in terms of angle and offset.

Symptoms:

High axial and radial vibration at 1x RPM of the driver or driven system.

The vibration is more important in axial than in radial direction (this fact allows to
discard unbalance).
 Uneven wear in axial direction on pulleys and belts.

Figure 6.7: Misaligned pulleys

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