Alignment
Shaft alignment can be performed with a lot of tools. The easiest way is to use a ruler or a
straight edge over the two coupling halves and align by eyesight. The result is not very
accurate and it is operator dependent. To achieve a better result is to use dial indicators. A
skilled and experienced user can achieve good and reliable result, but it takes time. The
easiest way and most accurate is to use laser based alignment systems. They do not require
special skill and delivers very accurate and repetitive results.
Definition of Misalignment:
Misalignment is the deviation of the relative shaft position from collinear axis of rotation when
the equipment is running at normal operating condition.
Types of Misalignment:
(1) Parallel or Off-set: It occurs when the shaft centerlines are parallel but
displaced from one another. Parallel misalignment consumes more power than angular
misalignment.
(2)Angular misalignment:- It occurs when two shafts are joined at a coupling in
such a way as to induce a bending force on the shaft. Angular misalignment affects pin bush
coupling more than tyre coupling.
(3) Skew:- Combination of offset & angular misalignment. This most common type of
misalignment.
Causes of misalignment:
1. Poor workmanship during alignment.
2. Improper foundation or larger holes for holding down bolts.
3. Thermal expansion due to a process heating. Most machines are aligned cold, and then
as they operate and heat up thermal growth causes misalignment.
4. Vibration due to unbalance, bearing problems etc.
5. Forces transmitted to the machine by piping and support members.
6. Machines directly coupled not properly aligned.
Effects of misalignment:-
1. Most experts agree that 50% of machinery problems are caused by misalignment.
2. Misalignment usually causes the bearing to carry a lesser or higher load than its design
specification. Higher load in turn causes bearing failure due to fatigue.
3. Misalignment causes vibration, which destroys the critical parts of the machine such as
bearings, seals, gears, couplings etc. These failures are sometimes not identified and
analyzed as normal wear and tear.
4. Misalignment causes damage in the outer race of the bearing.
5. Misalignment break the lubricant film inside the bearing and increase friction between
rotating or moving parts. This results higher power consumption.
6. Misalignment increases 2-17% power consumption.
7. Misalignment will increase the operating temperature of the machine.
8. Misalignment generates heat in the coupling.
Alignment Methods:-
(1) Approximate or Rough Alignment:-
(a) Use of Straight Edge, Taper Gauge & Filler Gauges:-
Using straight edge & filler gauge top & bottom coupling gap can be measured & adjustment
can be done accordingly. When these instruments are used for alignment face and rim
readings are affected considerably by-
(1) Smoothness of coupling surfaces.
(2) Trueness of coupling bore (concentricity and angularity).
(3)Differences in outside diameters (OD) of the coupling halves.
(b) Twin Wire Method:-
In this method two wires are fixed on two shafts and after rotating 180 0 the offset & angular
misalignment can be measured.
This method can be effectively used to perform rough alignment when the coupling halves are
very close to each other.
(2) Precision Alignment:-
(a)Face & Rim Dial Indicator Method:-
It is most probably the most widely used and oldest dial indicator method. It can be
used to take the face readings on the largest possible diameter on the face of the
coupling hub and be sure to measure and record this diameter for calculating the
equipment moves to improve the shaft alignment.