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
