IMPROPER SHAFT ALIGNMENT

In rotating machines coupled to a prime – mover, improper

Shaft Alignment contributes directly or indirectly to over éÍÓ
40% of failures of bearing, seals, spiders, couplings etc. ÔxÒ éÍÓ
This includes Pumps, Gearboxes, Compressors, Turbines,
Generators. It is a tricky subject, most often not understood C-1
properly; hence avoided by technicians. Both the tool used ÏâÒëï .05
C-2
ÊâÒëï ÏâÒëï ÊâÒëï
and the technique employed is equally important. The
technique can be learnt provided the proper tool is available.
It is like DRIVING A CAR, you first need to have a good
condition car, driving is a matter of training & practice. Ìä¿ë Ìä¿ë
Briefly we describe techniques used in Industry to do shaft Alignment.
1) STRAIGHT EDGE/HACKSAW BLADE (ABSOLUTELY CRUDE)

RADIAL AXIAL RATING 1/10

C2 Straight Straight
C1
Edge Edge
Accuracy of method 0.2 to 0.5 0.2/0.5
Alignment Required 0.05mm 0.05mm
1 2 3 4 5 6 7 8 9 10
DRIVER DRIVEN Cost A few Rupees

2) MAGNETIC VEE BLOCK + VERNIER : Radial Readings are taken by a Magnetic vee block, Axial by Vernier
Ref. Fig 2.
RADIAL
ON
OFF DIFFICULTY : .
C1 C2 a) Requires minimum ground clearance 'H' of 150mm, not suitable for small
AXIAL motors. .
b) Not suitable for couplings not having spacer. Only radial reading can be
taken in this case. This includes Lovejoy, Pin-bush, Tyre etc. .
00 10
10 20
20
30
30
c) Magnetic Vee Block can tilt at 180° due to weight. This gives a wrong
Reading Ref. Fig. 2 (b). Sometimes the Vee block falls off. MAGNETIC
VEEB BLOCK IS NOT SUPPOSED TO BE ROTATED. It is made for
Fig. 2 (a)
applications when magnetic vee block is fixed to a datum & job to be
measured is moved /rotated. .
d) Accuracy of Axial Reading depends on skill of operator. Ref. Fig.-2(a)
C1 C2
AXIAL RADIAL AXIAL RATING 4/10
Accuracy of method 0.3/0.4 0.2
OFF
H Alignment Required 0.05mm 0.05mm
ON
1 2 3 4 5 6 7 8 9 10
RADIAL
Cost 2,000 to 3,000 Rupees + cost of Vernier.
Fig. 2 (b)

3) FABRICATED CLAMPS : A clamp is fabricated from a 2.0mm/3.0mm sheet Ref. Fig. 3

RADIAL
DIFFICULTY: .
CLAMP
a) You need a separate clamp for each type of Coupling. ØA is as per
COUPLING 3mm AXIAL
NUT-1 NUT-2
coupling hub. Storing and retrieving this clamps is a problem
øA
b) Not suitable for couplings not having spacer. Only radial reading can be
Fig. 3 (a)
taken in this case. This includes Lovejoy, Pin-bush, Tyre etc. .
CLAMP DRIVEN c) RIGIDITY OF CLAMP IS VERY LOW. Gives high sag. This means a wrong
C2 Radial reading. Ref. Fig. 3 (b). .
COUPLING AXIAL d) Repeatability of readings is low. Each time you tighten NUT-1 & NUT-2
reading changes Ref. Fig. 3 (c). .
GAP

øA RADIAL
L (Cantilever) RADIAL AXIAL RATING 6/10
180°
Fig. 3 (b) Accuracy of method 0.1/0.2 0.1/0.2
Alignment Required 0.05mm 0.05mm
RADIAL 1 2 3 4 5 6 7 8 9 10
CLAMP GAP
Cost Eg.-1 Rupees 400 x 12 clamps = 4800
COUPLING AXIAL C2
(A few hundred Rupees x number of clamps made)

øA

Fig. 3 (c) DRIVEN

4) Aluminum Vee blocks with Studs & *Spirit levels Ref. Fig. 4
THIS GIVES EXCELLENT REPEATABILITY & ACCURACY. Fixture is rigid, versatile & precise.
Suitable for non spacer couplings like Lovejoy, Pinbshe, Tyre etc. by using additional vee block

RADIAL AXIAL RATING 9/10

Accuracy of method 0.05 0.05
Alignment Required 0.05mm 0.05mm 1 2 3 4 5 6 7 8 9 10

Cost 4,000 to 8,000 Ôë»äÌ ÍìÖâ ÕÖèÔ

* Sprit levels facilitates measuring 90°, 180°, 270°
0° reading precisely, since in a round object measuring
at 180° or at 170° or at 185° mens different readings.
Ref. Fig. 4 (b) THIS FEATURE IS UNIQUE TO THIS
180° CLAMP
** You can use digital dials instead of analogue.
This makes the procedure very easy.
Fig. 4 Fig. 4 (b) Cost of digital dials is appx. Rupees 6000 each

5) LASER ALIGNMENT: There are no dials, you only need to rotate 0-180°C & all readings are
available on digital output screen, very accurate, very precise, very costly
RADIAL AXIAL RATING 10/10
Accuracy of method 0.01 0.01
Alignment Required 0.05mm 0.05mm
Cost A few Lakhs 1 2 3 4 5 6 7 8 9 10

SPIDER
IMPROPER SHAFT ALIGNMENT
SPACER
COUPLLING
Cost = Material + Labour + Downtime

SPIDER
COUPLLING *VIBRATION
LIFE OF SPIDER
Cost = Material + Labour + Downtime
Cost = Material + Labour + Downtime

DECREASES BY
30-50%

BOLTS OF MOTOR, LIFE OF BEARING FATIGUE FAILURE **POWER DRAWN

PUMP GETS LOOSENED REDUCES 30-50% OF SHAFT BY MOTOR INCREASES
3-4%
SPIDERS TO BE IF SPIDER NOT
REPLACED REPLACED IN TIME ALIGNMENT GETS REPLACE BEARING MACHINE SHUTDOWN
COUPLING GETS DISTURBED MOTOR GETS HEATED
DAMAGED
MACHINE SHUTDOWN REPLACE SHAFT
DAMAGE TO COUPLING COST? = 4 Rs./Unit
BEARING ETC.
RE-DO ALIGNMENT RE-DO ALIGNMENT
MACHINE SHUTDOWN
RE-DO ALIGNMENT * VIBRATION IS LIKE A CANCER. ** IMPORTANT FOR MOTORS
IT SPREADS RAPIDLY, DAMAGING 40 H.P. AND ABOVE FOR A
RE-DO REPLACE SPIDER/ 40 K.W. MOTOR POWER
ALIGNMENT COUPLING
ALL ROTATING ELEMENTS.
GENERALLY ALLOWED VALUE IS LOSSES IS APPX. Rs. 100/-
UPTO 5mm/Sec. PER DAY
DRIVER DRIVEN DRIVER DRIVEN
Radial
Rim Axial
0 Rim
0
0º
0º

Pos2 +0.3 270º 90º --0.3

--0.25 270º 90º +0.2 Pos1

W Dial gauge
180º Face 180º
Pos2 Pos1
Face
Dial gauge +0.2
--0.3 W

Radial Axial
At the heart of a rotating machine having couplings is Alignment. The savings which accrue by doing proper alignment is beyond your imagination.