ALIGNMENT

1
ALIGNMENT
2
1- Introduction
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What is shaft alignment
It is collinear of two center lines
Shaft alignment is the proper positioning of the
shaft centerlines of the driver and driven
components (i.e., pumps, gearboxes, etc.) that
make up the machine drive train. Alignment is
accomplished either through shimming and/or
moving a machine component. Its objective is to
obtain a common axis of rotation at operating
equilibrium for two coupled shafts or a train of
coupled shafts.
4
Why it is important to make shaft alignment?
Shafts must be aligned as perfectly as possible
to maximize equipment reliability and life,
particularly for high-speed equipment. Alignment
is important for directly coupled shafts, as well
as coupled shafts of machines that are separated
by distance spool (those using flexible
couplings). It is important because misalignment
can introduce a high level of vibration, cause
bearings to run hot, and result in the need for
frequent repairs. Proper alignment reduces power
consumption and noise level, and helps to achieve
the design life of bearings, seals, and couplings.
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2-Types Of Couplings
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1 -Rigid Couplings It is a metal to metal
contact (100 collinear)
2 -Flexible Couplings Spacer with shims
Gear Grid Rubber Others Torque converter
Alignment
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It is collinear of two center lines
Motor
Equipment
Coupling
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Pump Grouting
Special grouting concrete
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1 -Rigid Couplings
Driver
2 Flexible Couplings
Spacer with shims
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Spacer with shims
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Spacer with shims
Spacer is not connected directly to both hubs,
but through the shims
Driver
Equipment
12
Gear
13
Grid
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Torqueconverter
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Pumps
Turbine
MOTION
MOTION
HYDRAULIC ENERGY
HYDRAULIC ENERGY
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Normal speed
Higher speed
Lower speed
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Guide Vanes
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3- Alignment Preparation check list
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Alignment Preparation check list
Comments
Description
N/A
OK
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Comments
Description
N/A
OK
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Alignment Handing over check list
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Comments
N/A
Handing over check list
OK
Confirm driver has been installed and initial
alignment completed and accepted.
13
Confirm suction and discharge nozzles are
installed as per design and alignment is correct
and stress free.
14
Confirm pipe strain checked and corrected.
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Confirm free rotation and correct direction is
clearly marked.
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Confirm bearings and seals are clean and free
from damage
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Confirm coupling hubs are clean damage free and
match marked.
Confirm that after final code alignment with pipe
work is connected, the misalignment tolerance is
maintained after releasing spring pipe supports
.
18
Ensure guards are fitted and in accordance with
area design requirements
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CHAPTER 2
1-Types of Alignment
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Parallel misalignment
Vertical
OR
Horizontal
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Angular Misalignment
Vertical
Equipment
OR
Driver
Horizontal
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Correcting of Misalignment
I- Vertical Plane
A- Parallel Misalignment
Equipment
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I- Vertical Plane
B- Angular Misalignment
Equipment
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II- HORIZONTAL Plane
A- Parallel Misalignment
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29
II- HORIZONTAL Plane
A- Parallel Misalignment
29
30
II- HORIZONTAL Plane
B- Angular Misalignment
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31
31
32
32
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2- Dial indicators Types and Functions.
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Dial indicators Types and Functions

• 1- Balanced-Type

Negative direction Stem moves out
positive direction Stem moves in
-10
10
-20
20
30
-30
40
40
-50
50
35

• 2 - Continuous Type

10
190
20
180
30
170
40
160
50
150
140
60
130
70
80
120
90
110
100
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CHAPTER 3
1- Preparation on Alignment
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Measure and correct
Pipe strain
Soft foot
Run out
Thermal growth
Mechanical centre
Magnetic centre
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Pipe strain
Maximum 0.002 in
EQUIPMENT
PLANT LINE
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Soft foot
Maximum 0.002
One driver leg is not settled on the base
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Run out
Maximum 0.002
EQUIPMENT SHAFT
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Thermal growth for hot liquid pumps
1- Apply the alignment procedure for the pump at
ambient Temp. 2- Heat up the pump by opening the
start up bypass for ½ hrs. 3- Put the dial
indicator on the coupling rim and adjust to zero
reading 4- close the bypass 5- Take the dial
indicator reading after 24 hrs. 6- This reading
is the thermal growth 7- Add the thermal growth
reading as a shims under the driver legs
X Thermal growth
Equipment
Driver
42
Thermal growth for Compressors
1- Apply the alignment for the compressor at
ambient Temp. 2- Go to manufacturer catalogue
and read the thermal growth amount. 3- Add the
thermal growth reading as a shims under the
driver legs
After minutes of Starting
Equipment
X Thermal growth
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This design is to avoid any thermal growth
As thermal expansion will be in all directions
Equipment
43
44

• Magnetic centre.

Electrical motors have no thrust bearings as they
have instead a magnetic center
Driver
44
45
Measurement of bar sag.
The attachment that will be used
Piece of Pipe
Bar Sag on 12 O'clock Position
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Piece of Pipe
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2-How To Do Alignment
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Driver
Equipment
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49
Driver
Equipment
Driver
Equipment
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VERTICAL READINGS
Parallel actual misalignment
x
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HORIZONTAL READINGS
Parallel actual misalignment
x
If both shafts rotate or one shaft rotates,
the dial indicator reading is the same, and is
equal to double value of the actual
Misalignment amount
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1-Reversal Alignment
F
Driver
Equipment
M
53
F
M
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PARALELL READINGS
12 Ock
12 Ock
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6 Ock
6 Ock
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PARALELL READINGS
12 Ock
12 Ock
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6 Ock
6 Ock
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CHAPTER 4
1-Reversal AlignmentCalculation Method
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(No Transcript)
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VERTICALLY
X
Inboard
MV
FV
FV
F
M
58
59
VERTICALLY
Y
Out board
FV
MV
FV
F
M
59
60
D1 4 in D2 8 in D3 16 in
Sag ( 0 )
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2-Reversal AlignmentGraphical Method
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Vertically
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EXAMPLE
FV 18 mils MV 32 mils
Remove shims
F
M
Add shims
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Horizontally
64
5/3/2006
65
EXAMPLE
FH 10 mils MH 20mils
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3-Reversal Alignment Software
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Rim and Face Alignment
P Parallel Reading A Angular Reading
Driver
Equipment
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OR
A
P
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69
PARALELL READING
12 Ock
3 Ock
9 Ock.
6 Ock
69
70
ANGULAR READING
12 Ock
6 Ock
70
71
ANGULAR READING
3 Ock
9 Ock
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CHAPTER 5
1-Rim and FaceAlignment Calculation Method
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CALCULATION METHOD
A ANGULAR READING
P PARALLEL READING
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VERTICALLY
X
Inboard pv

AV
D
AV
PV
Outboard
Inboard
D
X
PV
Y
75
P
A
0
0
0
0
-14
8
-6
-16
75
76
X 4 in Y 12 in D 4
in Sag -1
P
A
0
0
0
0
-14
8
-6
-16
VERTICALLY
HORIZONTALLY
76
77
2- Rim and Face Alignment Graphical
Method
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Vertically
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EXAMPLE
AV - 16 mils PV - 2 mils
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Horizontally
80
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EXAMPLE
PH - 7 mils AH 8 mils
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Horizontally
If PH 7
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3-Rim and Face Alignment Software
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CHAPTER 6
1- Optical Alignment
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Optical Alignment
M
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(No Transcript)
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(No Transcript)
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Transducer
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REFLECTOR
Rotate the side thumb Wheel to raise or lower
the reflector
This lever to lock The reflector position
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REFLECTOR
VERTICAL ADJUSTMENT
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OFF Beam misses detector Red Blinks
quickly Green Is OFF
OFF
END Beam hits non linearized area of
detector Red Green Blinks quickly
Alternatively
END
COORDINATES Beam hits area of detector Red
Green Blinks Slowly
Together
-2 1
92
1- PREPARING FOR ALIGNMENT PROCEDURE
a- Solid flat foundation
b- Machine mobility ( 2 mm higher screw type
positioning )
c- Soft foot ( Must be checked immediately)
d- Thermal growth
93
HORIZONTAL MACHINE ALIGNMENT
1-Transducer to reflector
2-Transducer to coupling center
3-Coupling diameter
4-RPM
5-Transducer to front feet
6- Front feet to rear feet
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DIM
CONFIRM EACH ENTERY WITH ENT
1
2
3
4 RPM
5
6
95
DIM
96
DIM
97
DIM
BEAM DEFLECTOR
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DIM
99
5-Laser beam adjusting
Rotate the side thumb Wheel to raise or lower
the reflector
This lever to lock The reflector position
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CHAPTER 7

• Case Studies
• For Alignment
• Failure

101
A- Bearings Failure
102
THRUST BEARING
RADIAL BEARING
ball Bearings
roller Bearings
Tilting pad Bearings
103
DRIVE END
NON-DRIVE END
HANGED BEAM IMPELLER
104
Thrust Ball Bearings
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(No Transcript)
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(No Transcript)
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(No Transcript)
108
Mechanical seal and bearings arrangement
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THRUST PAD BEARING
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THRUSTCOLLAR
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(No Transcript)
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(No Transcript)
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Titan 130 Thrust Bearing
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(No Transcript)
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(No Transcript)
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Radial Tilt-Pad Bearing
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RADIAL TILTING PAD BEARING
118
Oil Wedge
Friction Effect
Oil Wedge Effect
Shaft
119
Oil Wedge
Oil adhere to the rotating shaft
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RADIAL TILTING PAD BEARING
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B- Pumps Cavitations Failure
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IN PUMPS
123
CAVITATION CAN OCCUR in
AND
124
What is cavitations phenomenon
It is an action of fluid vapor attack on the
parts of equipment which produce suction
pressure less than vapor pressure of the pumped
fluid.
125
This action will cause loss of the
weakest component element of suction parts
material due to bubble explosion on the surface
of suction parts causing cavities .
Vapor bubble explosion on the parts surface
could be 10,000 psi.
126
(No Transcript)
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Pump suction parts
128
LOST ELEMENTS IN SUCTION PARTS
CARBON STEEL CAST IRON STIANLESS STEEL
BRONZ BRASS
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Cavitations effect on an impeller, indicated by
the cavities appearance of cavitated regions on
the surface
130
Damage to the pressure side of the vane from
discharge recirculation
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(No Transcript)
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What is Cavitations Effect
1- CENTRIFUGAL PUMPS
Impeller deterioration
Decrease discharge pressure
Decrease pump flow rate
Increase vibration level
Bearings M/S failure
133
2- RECIPROCATING PUMPS
Suction valve deteriorations
Spring Rupture
Decrease discharge pressure
Decrease pump flow rate
Cylinder Head Damage
Piston Damage
134
NPSH
1- NET POSITIVE SUCTION HEAD REQUIRED
YOU CAN GET FROM PUMP MANUAL
2- NET POSITIVE SUCTION HEAD AVAILABLE

YOU CAN CALCULATE FROM PUMP SITE
135
What is the parameters affecting
NPSHA
SUCTION PIPE LENGTH
SUCTION PIPE DIAMETER
LIQUID SPECIFIC GRAVITY
INTERNAL SURFACE OF SUCTION PIPE
LIQUID SURFACE ALTITUDE
VAPOR CONTAMINATION
SUCTION PIPE LEAKS
SUCTION PRESSURE
LIQUID TEMPERATURE
LIQUID VISCOCITY
LIQUID VAPOR PRESURE
ATMOSPHERIC PRESSURE
136
HOW TO IMPROVE NPSHA
SHORTEN THE SUCTION PIPE LENGTH
INCREASE SUCTION PIPE SIZE
DECREASE SUCTION LIQUID TEMP.
DECREASE SUCTION NEGATIVE ALTITUDE
INCREASE SUCTION POSITIVE ALTITUDE
STOP THE PIPING SUCTION LEAKS
RENEW THE SUCTION PIPE
137
NET POSITIVE () SUCTION HEAD
Z liquid surface height ft
PS Pump suction pressure psig
V liquid velocity
ft/sec
Pf Friction Pressure drop psi
Pa Atm. Pressure psi
Vp Vapor pressure psia
h L Suction head loss ft
g 32.2
ft/sec.sec
138
EQUATION DIMENTIONS
NPSHA
( ft )
2
V
P sva Vp 2.31
hL

Z

-
2g
Sp.gr
2
2 V
2
ft
ft
sec
2
sec



( ft )
2g
ft
ft
2
2
sec
sec
Lb
3
ft
P
2
ft


( ft )

Sp.g
Lb
2
ft
3
ft
139
NPSHA
IS
NOT
OR
140
1
General Equation
V
141
IF The Suction pressure is known
P sva
Vp 2.31
Psa

Sp.gr
142
2
If The Suction pressure is known
NPSHA
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Boiled water
Positive Reading
PS
Z
Z lt hL
CAVITATION OCCURED
144
PS
Negative Pressure
NO CAVITATION
PS
145
SUCTION NEGATIVE ALTIDUDE NOT MORE THAN 6
METERS
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ATMOSPHERIC PRESSURE
10,033 mt OF WATER
SPACE
SPACE
76 Cm MERCURY
water
ATMS
ATMS
147
Pump Eff. 100
PS
VACUUM
PS
10,033 mt OF WATER
PS
ATMS
148
CENTRIFUGAL PUMPS LOSSES
H ft
10 20 30 40 50
60
Q g.p.m.
100 200 300 400
500
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PS
PS
6 mt WATER
PS
150
VAPOR PRESSURE
1- Heat up a little of water in a pot up
to boiling point 100 C ( valve 1 is
opened)
2- Take off the heating source,
simultaneously close valve 1.
151
3- During cooling down, Start to record the P
Gauge relevant to Temp.
152
Vapor Pressure
5- Record the Absolute Liquid vapor
pressure.
153
Vapor Pressure
The absolute pressure exerted by the equilibrium
vapor of a liquid when confined in a closed
Previously evacuated tank
GPSA 1-7
Liquid vapor
Liquid
T CONSTANT
154
( Neglect velocity head (
Solution
8 31 - 12
27 ( ft )
Compare with NPSHR
155
( Neglect velocity head (
Solution
8 2 - 2
8 ( ft )
Compare with NPSHR
156
Examples
If the liquid level
Z - 12 ft

is 1 ft of liquid
, Friction loss
, Atmospheric pressure is
( Neglect velocity head (
, water sp gr. is
,Vp 3.7 psia
FIND NPSHA
Solution
12.8 ( ft )
Compare with NPSHR
157
( Neglect velocity head (
FIND NPSHA
Solution
16 . 46 ( ft )
Compare with NPSHR
158
( Neglect velocity head (
FIND NPSHA
Solution
( - 6.6 ) ( ft )
Compare with NPSHR
159
Examples
If the liquid is butane and level is
z - 8 ft
System pressure is 60 psia.
Temperature is 90 F
( Neglect velocity head (
Vp 44 psia at 90 F, butane sp.gr is 0.58
FIND NPSHA
Friction loss 12 ft of liquid,
Solution
43.7 ft
Compare with NPSHR
160
( Neglect velocity head (
FIND NPSHA
Solution
7.33 ( ft )
Compare with NPSHR