INTRODUCTION to BASIC ALIGNMENT

What is Machinery Alignment?

Collinear

shaft centerlines under normal operating conditions

Normal load, temperatures, pressures, flow

Types of Misalignment
Offset

(parallel)

Angular

Types of Misalignment
Combination

(Parallel and Angular)

Axial

(coupling gap incorrect)

Offset (Parallel) Misalignment

Vertical Plane

Offset (Parallel) Misalignment

Horizontal Plane

Angular Misalignment

Vertical Plane

Angular Misalignment

Horizontal Plane

Combined Misalignment

Vertical Plane

Problems Caused By Misalignment

High

Axial / Radial Vibration High Bearing Temperatures Bearing and Seal Wear / Failure Coupling Wear / Failure

Problems Caused By Misalignment

Axial Misalignment Coupling Gap Must Be Correct Or Flexible Element Will Fail Shaft

Cracks Other (rubs, instability, etc.)

High Axial / Radial Vibration

Vibration Behavior Depends On:

Amount and Type of Misalignment Coupling Type Foundation and Grouting Condition Soft Foot and Casing Distortion

High Bearing Temperatures

Preload: A Uni-directional Steady State Force Misalignment Can Significantly Increase Bearing Preload
Higher

PSI loading on Babbit Surface Increased Friction

Heavily loaded bearings may exhibit higher than normal metal temperatures

Bearing and Seal Wear / Failure

Fluid

Film Bearings:

Polishing Wiping
Rolling

Element Bearings:

Shortened Life Span

Fluid Film Bearing Failure

Tilt-Pad Bearing With Localized Wiping

Rolling Element Bearing Life Calculation

Hours of life L10 = for 10% failure rate

16,700

dynamic capacity x load rating

L10 =
rpm

FORCE

Problems Caused By Misalignment Coupling Wear / Failure Gear Tooth Failure

Gear-Type Coupling

Shaft Cracks

Other Problems Caused By Misalignment

Rubs Seal Rubs Bearing Rubs
Instability Unloaded Bearing

Other Problems Cause By Misalignment

High

Unbalance Response
Unloaded Bearing

Mechanical

Looseness

Misalignment Detection
Vibration

Data Shaft Average Centerline Position Bearing Metal Temperatures

Misalignment Detection
Casing

Expansion Trend Data Hot Alignment Monitoring Infrared Thermography

Misalignment Detection
Machinery

Inspection Maintenance History Mechanical / Metallurgical Inspection of Components

Misalignment Detection Contd

Axial

and Radial Vibration (1X, 2X) Orbits with High Degree of Preloading Abnormal Shaft Average Centerline Position

Vibration Data

High Axial Casing Vibration

Vibration Data

Figure 8 may occur at 1/2 of any resonance

Orbits With Increasing Preload From Misalignment

Shaft Average Centerline Position

Preloaded Orbit and Corresponding Shaft Average Centerline Plot

Bearing Metal Temperatures

RTD / Thermocouple Typical Babbit Bearing Metal Temperature: 160 F to 180 F

A Metal Temperature Approaching 220 F May Cause Failure Of The Bearing (babbit melts at 260 F , but will move at 240 F )

Bearing Metal Temperatures

Lube Oil Drain Temperatures Generally Unreliable:

Not a direct measurement

May be a common drain from several sources

Misalignment Detection Contd

Use Trend Data

During Loading Following A Cold Startup Thermal Growth Changes Occur Vs. Time Vibration Vs. Time Bearing Metal Temperatures Vs. Time

Misalignment Detection Contd

Casing Expansion

Unbound Axial and Radial Growth Dual Casing Expansion Determine Local Temperatures

Infrared Thermography

Misalignment Detection Contd

Piping Hangers

Should Not Oppose Thermal Growth Of Piping

Expansion

Joints

Allow Relief For Thermal Expansion

Flange

Bolts

Check For Loose Or Broken Bolts

Misalignment Detection Contd

Shims
No More Than 3-4

Check For Rust, Paint, Looseness

Dowel Pins Check For Loose, Damaged, Missing Pins

Misalignment Detection Contd

Maintenance History

Machine Reliability Repeated Failure of Components? Alignment Readings Changes to Alignment

Misalignment Detection Contd

Mechanical / Metallurgical Inspection Of Worn Components

Couplings Bearings Seals

Misalignment Detection Contd

Use and correlate all information