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Coupling Alignment
May 25, 2018 • 22 likes • 10,250 views

AI-enhanced description

This document discusses sha! couplings

and alignment. It describes di"erent
Readtyp…
more

A Ashish Kumar Jain

PROBLEMSINCOUPLINGS

•Crackoncouplings.
•Couplingslooseonshaft.
•Holesbecomingoval.
•Couplingedgedamage.
•Key&Keywaydamage.
•BothcouplinghalvesnotequalinOD.

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 DIALGAUGEREADING
READING-+0.83

LargePointer=0.00
SmallPointer=3-4

Readingcalculations:
Pump Motor
Vertical. Vertical.
+0.04 +0.02
-0.00 -0.00
+0.04 +0.02
Sag NIL Sag NIL.
+0.04/2= +0.02 +0.02/2= +0.01
Horizontal. Horizontal.
Near-0.02 Near+0.06
Far(-)+0.03(-) Far(-)+0.04(-)
-0.05/2= -0.025 +0.02/2= +0.01
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Standards

Coupling Alignment
1. COUPLING AND ALIGNMENT.
2. COUPLING is the device used to join two sha!s say, the
Driver and the Driven to transmit power. Functions of Sha!
Couplings To provide connection and Dis connection
between the driver & follower. To provide Alignment
facilities. To allow flexibility between sha!s. To reduce
transmission of SHOCK loads. To introduce protection
against overloads. To alter vibration characteristics of
rotating units.
3. Requirements of a good Sha! Couplings 1. It should be
easy to connect and dis- connect. 2. Should be able to
transmit full power. 3. Should hold sha! in alignment. 4.
Should be able to reduce the shock loads. 5. Should have
no projecting parts. 6. Should have smooth surfaces.
4. FLANGE SLEEVE MUFF COUPLINGS RIGID FLEXIBLE
KNUCKLE OLDHAM METALIC NON-METALIC GRID CHAIN
GEAR PAD BUSH TYRE SPIDER
8. Pin & bush Flexible coupling.
9. Pin & bush Flexible coupling.
10. Pin & bush Flexible coupling.
11. Steel Grid or BB coupling.
12. TYRE COUPLING.
13. GEAR COUPLING.
14. Material for Flexible elements. • STEEL. • PLAIN
RUBBER. • SYNTHETIC RUBBER. • LEATHER. • TEFLON. •
PLASTIC.
15. a) REMOVAL. a) Never remove by hammer blow. b)
Use conventional pullers. c) Hydraulic jack can be used. d)
If needed, removal by heating can be done, but with great
care not to damage the sha!.
16. b) REFITTING. a) Clean Sha! surface & Coupling bore.
b) Measure the bore & sha! OD to check tolerance. c) Do
not use a coupling if it has any cracks. d) Always change
coupling in pairs. e) Check coupling OD for trueness & out
of roundness. f) If high interference fit is needed, couplings
can be heated in an oil bath up to 120°C. g) Check Key &
Keyway for proper fit. h) Use pushers for fitting. DO NOT
HAMMER. i) Fit coupling face perpendicular to the sha!
axis.
17. PROBLEMS IN COUPLINGS • Crack on couplings. •
Couplings loose on sha!. • Holes becoming oval. •
Coupling edge damage. • Key & Keyway damage. • Both
coupling halves not equal in OD.
18. HYDRAULIC COUPLING • A hydraulic coupling consists
of two identical halves, one fixed to the driving sha! A and
the other to the driven sha!.B Both these halves are
housed in a common casing, filled with oil.which is used as
a working medium. A is in the form of pump impeller and B
is in the form of a turbine runner. • When A rotates, oil is
forced out through the periphery of the pump impeller.
The oil enters the turbine runner and makes it to rotate. In
actual practice, the speed of B is less than that of A by 2 to
4 % • E"iciency ή = Pb/Pa = Nb/Na • Slip s = 1 – ή = 1 –
Nb/Na
19. Hydraulic Coupling A B
20. Hydraulic Torque Converter • A hydraulic torque
converter is an improved form of hydraulic coupling. In
this, the Torque ( or Speed) of the driven sha! may be
increased o0r decreased. It is achieved by providing a third
member in between the pump impeller and the turbinr
runner, known as guide ring. It consists of a series of fixed
guide vanes, whose function is to change the direction of
oil, which multiplies the speed of the runner.
21. ALIGNMENT. Alignment is the adjustment of relative
position of 2 coupled machines, so that the centre line of
the axis will be concentric when the machines are running
during NORMAL WORKING CONDITIONS. Misalignment
may be :- • PARALLEL. • ANGULAR. • COMBINED PARALLEL &
ANGULAR.
23. Consequences of misalignment. • A) Reduction in
bearing life. • B) Coupling degradation. • C) Sha! fracture. •
D) Vibration. • E) Other rotating part failures.
24. CHECKS BEFORE STARTING ALIGNMENT. • Coupling
gap. • So! foot. • Indicator sag. • Dial indicator rigidity. •
Alignment readings. (0°, 90°, 180°& 270°) • Thermal growth.
(Steel-0.01mm/M for 1°C rise in temperature.) • Sleeve
bearing o"set.
25. ALIGNMENT : SOFT FOOT SOFT FOOT is the condition,
when all feet of the Pump or Motor are not in one plane.
26. ALIGNMENT : How to Detect SOFT FOOT ? • Put
Machine on base. • Do not tighten bolts. • Attempt to pass
thin Feeler Gauge Blade under a Foot. • If the blade passes,
that foot has So! Foot. • Check other feet.
27. ALIGNMENT : How to Rectify SOFT FOOT ? • Measure
So! foot gap. • Tighten all hold nuts • Put Dial Gauge on
each foot & loosen the Bolt. • If foot rises, put Shims. •
Repeat process for each foot. • Always tighten bolts in one
sequence.
28. ALIGNMENT : SOFT FOOT. • SOFT FOOT is the
condition, when all feet of the Pump or Motor are not in
one plane or Poor surface contact between the underside
of the Machine or Motor and the base plate or frame.
29. ALIGNMENT TOLERANCES : 0.013 to 0.0254000 - 6000
0.025 to 0.052000 – 4000 0.05 to 0.101000 – 2000 0.08 to
0.11<1000 TOLERANCE (mm)MACHINE RPM
30. METHODS OF ALIGNMENT : • Straight Edge, Feeler
Gauge & Level. • Mathematical Method. • Reverse Indicator
Method (graphic) • Face & Rim Alignment. (graphic) •
Across Flex element. (graphic) • Laser Beam Method.
31. PRELIMINARY ALIGNMENT : Straight Edge -
32. PRELIMINARY ALIGNMENT: Feeler Gauge
33. ACCURATE ALIGNMENT : Done with the help of DIAL
GAUGES.
34. DIAL GAUGE READING 1 0 0 20 -80 10-90 -70 30 -60 40
-50 50 -30 7080 -20 90-10 -40 60 1 2 345 TOP Large
Pointer = 0.00 Small Pointer = 3
35. DIAL GAUGE READING 1 0 0 20 -80 10-90 -70 30 -60 40
-50 50 -30 7080 -20 90-10 -40 60 1 2 345 FAR Large
Pointer = 0.00 Small Pointer = 2-3 READING - -0.60
36. DIAL GAUGE READING 1 0 0 20 -80 10-90 -70 30 -60 40
-50 50 -30 7080 -20 90-10 -40 60 1 2 345 BOTTOM Large
Pointer = 0.00 Small Pointer = 3 - 4 READING - +0.83
37. DIAL GAUGE READING 1 0 0 20 -80 10-90 -70 30 -60 40
-50 50 -30 7080 -20 90-10 -40 60 1 2 345 NEAR Large
Pointer = 0.00 Small Pointer = 2-1 READING - -1.075
38. DIAL GAUGE READING 1 0 0 20 -80 10-90 -70 30 -60 40
-50 50 -30 7080 -20 90-10 -40 60 1 2 345 TOP Large
Pointer = 0.00 Small Pointer = 3
39. ACCURATE ALIGNMENT : Dial Gauge -
40. 500 300 200 ACCURATE ALIGNMENT CALCULATION :
4.5 4.0 Coupling Gap Top= 4.5 mm. Coupling to Front Foot
= 500 mm Coupling Gap Bottom=4.0 mm. Front to Back
Foot = 300 mm Coupling Radius = 200/2= 100 mm. Total
distance = 800 mm
41. Alignment calculations Gap di!erence = 4.5 – 4 = 0.5 /
2 = 0.25 (A) a) Distance corrections = 800 / 100 = 8 (B) So (A)
x (B)=0.25 x 8 = 2 mm shim is to be given under each back
foot. b) Corrections when front feet are to be raised :-
Distance corrections = 500 / 100 = 5 (B) So (A) x(B) =0.25 x 5
= 1.25 mm shim is to be given under each front foot.
42. REVERSE INDICATOR ALIGNMENT METHOD. • Before
starting the alignment, the MASTER must be decided. The
other machine must be moved to align the sha!s. First
take the dial indicator readings on the pump coupling and
then the readings on the motor coupling. On a sheet of
graph paper, layout the equipment being aligned. The
scale used is one small division equal to 1 inch.or to any
suitable scale. Plot the distances.
44. TOP
45. FAR
46. BOTTOM
47. NEAR
48. Reading calculations : Pump Motor Horizontal. Near +
0.006 Far (-) +0.004 (-) +0.002 /2 = Horizontal. Near - 0.005
Far (-) - 0.015 (+) +0.010 /2 = Vertical. + 0.005 - 0.000 + 0.005
Sag (-)- 0.005 (+) + 0.010/2 = Vertical. - 0.025 - 0.000 - 0.025
Sag (-)-0.005 (+) - 0.020 / 2 = - 0.010 + 0.005 + 0.005 + 0.001
49. Pump to motor alignment guide. - Near side + Near
side- on bottom + on bottom + Near side - Near side+ on
bottom - on bottom - Near side - Near side- on bottom - on
bottom + Near side + Near side+ on bottom + on bottom
Reading on motorReading on pumpReading on
motorReading on pump Horizontal (Top view)Vertical (Side
view) Pump sha! Motor sha!
50. Reading calculations :
BottomTopBottomBottomPosition on graph. + 0.001+
0.005+ 0.005- 0.010Reading MotorPumpMotorPump
Horizontal.Vertical
51. P FFM BF P FFM BF HORIZONTAL SOLUTION VERTICAL
SOLUTION 0.010 0.019 0.007
52. Reading on pump. 0.00 + 0.04 + 0.03- 0.02 Reading on
motor. 0.00 + 0.02 + 0.04+ 0.06 Example – 2 Reverse
Indicator Method
53. Reading calculations : Pump Motor Horizontal. Near +
0.06 Far (-) + 0.04 (-) +0.02 /2 = Horizontal. Near - 0.02 Far (-)
+ 0.03 (-) - 0.05/2 = Vertical. + 0.02 - 0.00 + 0.02 Sag NIL +
0.02/2 = Vertical. +0.04 - 0.00 + 0.04 Sag NIL +0.04 / 2 = +
0.02 + 0.01 - 0.025 + 0.01
54. Reading calculations :
BottomBottomBottomTopPosition on graph. + 0.01-
0.025+ 0.01+0.02Reading MotorPumpMotorPump
Horizontal.Vertical
55. P M FF BF 0.125 P M FF BF 0.01 0.0455 Vertical
correction Horizontal correction 0.05 (Scale 1=0.005)
Distance : P M=130 mm; M FF=180 mm; FF BF= 330 mm.
Scale 1= 100 mm TOP BOTTOM FAR NEAR
56. Conclusion : Top – Bottom correction : • The motor
sha! : 0.05 shim is to be given under each front foot and
0.125 shim under each back foot Far – Near correction : •
The motor sha! has to be shi!ed towards near end. The
front feet by 0.01 and the back feet by 0.0455
57. MULTIUNIT ALIGNMENT • Plot all three units in a
single piece of graph paper using the reverse indicator
method. Unit 1 is master, there will be two lines for unit 2
and unit 3. Draw an alternate reference line close to the
actual position of the three units. Minimal movement is
required to get all units aligned.
59. Across the Flex Element
60. Positive reading means the intermediate sha! axis is
below the gearbox.
61. Negative reading means the intermediate sha! axis is
above Motor or the motor is below the intermediate sha!.
63. LASER ALIGNMENT TOOL S M S-unit on the master
machine. M-unit on movable machine.
64. Rough Laser Alignment 1. Turn sha!s with measuring
units to position 9 o’ clock. Aim the laser beams to the
centre of the closed target. 2. Turn sha!s with measuring
units to position 3 o’ clock 3. Check where the laser
hits.then adjust the beam half the travel in direction to
centre of the target. 4. Adjust the movable machine so that
the laser beam hits the centre.
66. Alignment and its e"ect on vibration. • Misalignment
causes vibration. • There is no 1 to 1 relation with amount
of misalignment and amount of vibration. • Misalignment
can cause failure of not only the coupling but also Bearings
and other moving parts. • Highest reaction is on the free or
outboard bearing instead of inboard end. • Misalignment
normally causes both Axial and Radial vibration.
67. OTHER SOURCES OF HIGH AXIAL VIBRATION. • Bent
sha!s. • Sha! in resonant whirl. • Resonance of some
components in axial direction. • Worn thrust bearing. •
Worn helical and bevel gears. • A sleeve bearing motor
hunting for its magnetic centre. • Couple component of
dynamic unbalance. (So high axial vibration should not be
concluded as the problem of misalignment only)
68. CHARECTERISTICS OF MISALIGNMENT. 1. 2xRPM
vibration. 2. Multiple harmonics. 3. Phase is the best
indicator. Phase di"erence across the coupling approaches
180 O (+ / - 40 O to 50 O )
69. One Event 1 Revolution Axial Direction Rigid sha!.
Flexible sha!. ANGULAR
70. ANGULAR MISALIGNMENT. 1. Primarily generates
high axial vibration at 1X & 2X rpm.. 2. Best detected by
180O phase change across coupling in axial direction. 3.
Amplitude of 2X or 3X RPM exceeds approximately 30% to
50% of that at # X RPM in the AXIAL direction
71. PARALLEL MISALIGNMENT. 1 st. Event 2 nd. Event 1
Revolution Radial Direction Rigid sha!. Flexible sha!.
72. PARALLEL MISALIGNMENT. 1. More Radial vibration.
2. It causes phase di"erence to approach 180O in
Horizontal direction. 3. 2X RPM exceeds 50% of 1X RPM.
73. MISALIGNED BEARING COCKED IN SHAFT.. 1. A cocked
bearing will normally generate considerable axial vibration
which a"ects 1X RPM & 2X RPM. 2. If phase is measured in
the axial direction at each of a 4 points 90O apart from
each other a cocked bearing will be indicated by 180O
phase shi! from top to bottomj and side to side.
74. COUPLING PROBLEMS 1. 2X RPM will o!en respond to
coupling problems. 2. In these cases both Radial and Axial
direction will show a fairly noticeable 3X RPM component.
75. Thank you ! Any questions please ? Presented by : A.
Jayprakash

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