Download - Advanced Alignment Alberta Module
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 1/31
Millwright
1
60403a
88880006877
+01
MILLWRIGHT
16403A
3.0 AD
ilrilililtil
ilililil
il Illlil tl
0888800068778
$4.68
Advanced
Alignment
Machine
Levelling
Fourth
Period
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 2/31
Advanced
Alignment
Rationale
l4/hy is it
important
for
you
to leurn this skill?
Aligning
two or more machine shafts that
are coupled together is
a
very important
skill to
have in
the
millwright
trade. Thermal
growth
and
process
forces
from
flowing
media
tend
to misalign
aligned
machines
when they are started and
placed
under
load.
Using the
Essinger
procedure,
along
with
graphs,
calculations and design
d,ata, it
is
possible
to
misalign
a
machine when it is
cold and
not
running
so
that
it
runs aligned at operational
temperatures. The desired end result is to have
very little
maintenance caused
by
alignment
problems.
Outcome
Wlten
you
huve completed
this
module,
you
will
be
able to:
Align
and then
purposely misalign a multiple chain of
cold, non-rotating machines to
a
very high degree of
accuracy
so
that the
rr-rachines
are aligned when
running
and
loaded.
Objectives
1. Revierv
safety,
rim and face and cross
dial shaft alignment.
2.
Explain the various techniques used to measure machine thennal
and
process
movement.
3.
Demonstrate graphical
solutions
for
solving multi-machine
shaft alignment.
lntroduction
You
need
to develop the
skill
of analyzing
and
solving
machine
shaft
to
shaft alignment
problems.
Alignment
solutions are developed and applied by logical
thinking and by
follou,ing
the strict
guidelines
set out in the
shaft alignment modules.
The procedures
followed
(such
as rim and face,
cross-dialing
and reverse
dialing)
use dial
indicators
to
measure
the degree
of misalignment
over specific
distances
to
determine
the
required
corrective
moves through
the formulae
or the
graph
methods.
The initial
result is
a
set
or
a
train of machines
that are coupled together in nearly perfect
shaft alignment
when
they
are
not running.
When the machines
are
energized
and
put
online
a
number of
things
happen
that
result in
the shafts moving out of
their ideal alignment
planes. In
other
words, the shafts become
rnisaligned.
This misalignment
is detrimental to the
life
of the
machine.
Thermal
Growth
or Shrinkage
Two
factors
that cause
a
machine
to move off its centreline are
lhermal
grou,th
or
shrinkage
caused
by the
expansion and contraction
ofmetal due
to temperature
changes.
Significant
temperature
changes may
take
place
u'ithin
a
machine
after it is
started
and
1 6tt403ap3.0.docx
O
2007.
Her Majestv the
Queen
in
right
ofthe
Province
ofAlberta
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 3/31
placed
under load.
The
temperature
may rise
due
to friction
or
to hot
materials
such
as
steam
rnoving
through
the machine.
An
example
of thermal
shrinkage
occurs
on
centrifugal
pumps
made
of stainless
steel
and designed
to
circulate
very
cold
brines
or
thermal
antifreeze
fluids.
The
reduction
in
pump
tenrperature
when
the
pump
is
operated
causes
tlre tnetal to shrink.
The Inost
accurate
rnethod
of
determinitrg
the
thermal
growth
of
a
rnachine
is
to
directh'
measure the
growth from
a
fixed
daturn
point
using optical.
rnechanical
or laser
measuring
instruments.
Moment
of Force
Another
factor
that
can move
a machine
off
its
centreline
axis is
a moment
of
force.
A
moment
of
force pushes
against
a
machine
to
force
or displace
it
off
of its principal
axis
ofrotation.
such
as
the force
created
by
high-pressure
steam
entering
one side
ofaturbine
pushing
it sideways.
Using engineering
design
data and formulas.
it
is
possible
to
calculate
the
degree of misali-enmerrt
due
to therrnal
grouth
and nrornents
of
force.
Once
the amounts
of movement
of the machines
are
calculated it rnakes
sense to
perform
cold
corrective
trloves
that are opposite
to
(or
counteract)
the thentral
growth
and rnornents
of
force
tnovetlents. The required
cold
corrective rnoves
result
in rnachine
shafts
and
couplings
being
purposely
misaligned
when not operating.
As
the machine repositions
(frorrr
temperature change or moment
of
force).
you
want
the shafts
and couplings
to
move
into almost
perfect
alignment.
For this
intentional
misalignment
of
cold
rnachines
to be
successful
it is imperative
that
the machine
foundation is
sound.
A crack or fracture
in a critical
location
within
the
foundatiorr
could alter machine
shaft positions
due to foundation
shifts. These
shifts may
be caused
by'hydraulic pressures
or
seasonal
shifting
ofthe
subsoils
adjacent
to the
foundation.
A
cold,
purposely
misaligned
tlachine
alignment
can be
checked
by
predicting
the cold
su'eep
readings.
These
readings
are
taken from
cross
dial
aligment
graphs (vertical
and
horizontal).
If
the cold misaligned
sweep readings
from
the unit
match
the
predicted
readings
from
the graphs
it
is
safe
to
assume
that the machines
have been
successfully
misaligned.
At this
point
the machine
should
be started and placed
under normal
load. As
the
n.rachines
heat
up
they exhibit
a
lou'er
vibration level
as they
come into
alignment.
This
is
good.
but
u'hat
happens
if
the
vibration
levels
steadily
increase?
At
some
high
vibration
lirnits
it
is
advisable
to shut
the rnachine
down
before
it fails.
At
this
noint
it
rnal'
be necessary
to
perform
a
hot
aligrunent,
u'hich
lneans
to
inspect
the
aligrunent
just
after
the machine
has
been
shut dou,n.
The
hot
aligmnent
inspection
rnay
reveal
that
the
machines
did not move
in the
directions
that were
anticipated.
A
good
rnethod
of
hot
alignment inspection
is
the most reliable
industry
standard, rvhich
is
called
rhe
Essinger
Tooling
Ball
alignment procedure.
The
Essinger
method can
be
used
to check
and
track transient lrlovements
u'hile
the machines
are hot and running.
Transient movelnents
are
machine
lrovements
that
are
not
non.nal
or predictable.
Several
otlrer methods have been
developed
to
check hot
alignrr-rents.
One
basic method
is
called
hot machine
olignntent
in.sltection,
uhich
means
that the
inspection is
performed
on the
machine
as
quickly
as
possible
after the
machine is
shut
down. The
brackets
and
dials
are
mounted
and
a
set
of su,eep
readings
are
quickly,
taken.
These
sweep
readings
change
constantly
because
the
n-rachine
is
cooling
down.
t'0.l03ap3.0.docx
C
2007.
Her Majesn
lhe
Queen
in right
of the Province
o{'Alhena
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 4/31
Objective
One
Llthen
you
have completed this objective,you
will
be uhle
to:
Review safety,
rim and face and
cross dial shaft aligrunent.
Safety
Obtain a
safe work
pennit
and
n'ork
order,
then lock out
the equipment
that
is
to be
aligned and
make ceftain that an
information
tag
is
placed
on the
locked
out energy
panel.
On
some
higher
voltage
panels,
a
racking out or
electrical
disconnect
procedure
rnust
be
followed.
Racking out,
locking
out and tagging the control
or
source
panel prevents
personal
injury
due
to
an
unplanned, unwanted equipment start-up.
The tag should have the
following
information:
r
the reason for the
lockout.
r
the
date
and
e
the
narne
ofthe
person
responsible
for the
lockout.
Keep in mind that the
energy source is not always
electricilv; it may be
petroleurn
fuels
or stearn. In the
case
ofnatural
gas,
diesel or
gasoline powered
engines,
it is necessary
to
isolate or
disable
the unit so
it cannot
start
when it
is rolled
over during
aligrunent
checks.
Steam
lines
entering
a turbine
must be closed and
chained
or
locked in the
closed
position.
In
some cases, a
slip
blind
can be
installed after
the
valve.
In
an
industrial
complex that controls machine operation thlough the use of
proqrarnmable
logic controllers
(PLCs)
or
distributive control
(DC)
systerns.
it
may be
necessarv
to request the control roorn
operator
to disable
the unit. The operator may
also
issue
a
safe u'ork permit
that
requires
motor control centre
(MCC)
panel lockout
for
a
specific
machine. The last inspection
before starting
an
alignment
procedure
is
to try to
test-start
the unit being
worked
on at the local command station.
Care
must
be
taken
when
preparing
special
types
of
process
equiprnent
for shaft
alignment.
An
example of this u'ould be
a
steam turbine
driving a
dynamic colt'lpressor.
In this case,
both the turbirre
and
the colnpressor must
be blocked
in
(r'alves
closed),
isolated.
bled
off
and
locked. The
reason
for
compressor isolation
and
lockout
is to
prevent
a
reverse flow
of
gas
through
the
compressor, which would result in
the
unit
running
backwards
at
high
speeds.
Hydraulically
driven
equipment
must
be
isolated
and bled
off so that no shaft
rotation,
other than
alignment rotation, takes place.
The equipment
must
be
isolated
by
locking the
valves
in
a
closed
position
and
bleeding
off trapped oil
to the
reservoir. Accumulators
should be
depressurizedby
bleeding
the
high-pressure oil to
the
resen'oir. In
cases
where
large
presses
are
used, it rnay be necessary to block
with
wood to
prevent
drift
due
to
gravity.
The reverse
flow of oil
through
a
pump
can
result
in the
purnp turning
in
reverse
and driving an electric motor.
I 60403ap3.0.docx
G
2007, Her
Majes$
the
Queen
in right
ofthe
Province
ofAlbena
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 5/31
The procedure
to lock
out valves
on a turbine/corlpressor
unit is
shown
in Fieure
l.
Compressor
TurbinelCampressor
Clcse and
lock
sleam thrc{lle
valves
Compressor Valves
1, Close
all
compressor
nl^-^
-.^^^,,"^
^^J
tuJU
iJ,
g)>ul
u
d;
lu
lockoul
vaive actuaiof.
1500$
Ste
am Inlet
$team Supply Valves
Close all steam supply valves
and
chain
and lock hand wheels.
d:scharger.valves
2. Shul
ofiand
lock
oLtt
pcwer
3. Close
and
iack
out
hanC
wheels and chaln
Figure
I -
Valves to lockout
on turbine/compressor
unit.
(Photographed
at Agrium
Redwater
Fertilizer
Operations)
Pneumatic
motors
that require
shaft
alignment
must
also be isolated
and
locked
out. The
lines
to and frorn
the
motors must
be
depressurized
so
that
the
potential
for
an
accidental
start
is eliminated.
Coupling
guards
and
safety shields must
be reinstalled
after
the
alignment
is completed.
Guards prevent
accidents that
could
be caused
by
human
contact
with
rotating
shafts and
couplings. Shields
prevent
accidental burns from high heat
sources such
as
engine
exhaust pipes.
I 60-l0jap3
0
docr
C
2007.
Her Majeso.the
Queen
rn
right of the
province
of Albe(a
d*ry
ffii
--'
'.
sf,
Siearn Supply Valve
Hand \{heel
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 6/31
Objective
Two
ll/hen
1,ou
huve
completed
this
objective.
you
will
be
able
to:
Explain
the various
techniques
used
to
measure
machine
thermal
and
process
lrovement.
Spindle
Shaft (Drive Shaft) Goupling
Atignment
You
may
be
required
to
align
an externallv
mounted
electric
motor
to
an
internally
mounted
gear
drive
unit,
as in
the
case
of
a
cooling
torver
fan
drive
assembly.
One
way
to
do this
is
to
use
two dial
indicators;
one
mounted
on the
face
of the
inboard
coupling
at
the
12
o'clock position
and the
second dial
on the face
ofthe
outboard
coupling
at
the 12
o'clock position.
See
Figure
2 for
arrangement
of
the
dials.
Dial
lr
j
l
Caupling
a
I
Li(
I
L-..,
I
L:B
n
u;,
-
Rnr
=
90"
-
1trn
-
/tK,
-
4nr
Coupling
a
Coupling
x----n*
Figure
2 -
Cooling
fan
drive.
The
spindle
shaft
alignment
rnethod
is
used
to negate
the effects
of
bar
sag
over long
distances.
This
method
of
alignment
will
correct for
angular
and
offset
misalignment
in
both
the vertical
and
horizontal planes.
The
rnethod
works
on the
assurnption
that
all of
the
n.risalignment
is
angular
and
the correction
takes place at the
two coupling
centrelines.
The
amount
of angular
misalignrnent
is measured
at both
couplings and
then.
using
sirnilar
triangles.
is
projected
back to
the motor feet
u'here
the
calculated
shirn
move
is
added or
removed
from Sl
and
S: locations.
This
shim
move u'ill
then result
in
the motor
shaft
centreline
being
coaxial rvith
the
gearbox
shaft centreline.
Her
Majesn, the
Queen
in right
of the
Province
of Alberta
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 7/31
Use
the
following
steps to calculate
the
shim one
and two and
side
to
side moves.
Step
One
The following
is
a
solution
for
Sr
and S: using
"A"
dial readings
and
dirnensions.
S,
=
TIR\
Lre
De
L,^
S,
=:qx
TIRo
'
DA
S,
=
TIRA
L.^ D^
L"^
Sz
==axTIR^
DA
Step Two
Use
the
follorr,ing formula to
solve
for
S
1
and
32
using
"B"
dial
readings
and
dimensions.
S,
=
TIRB
L,- De
T .^
S,
=:]g^TIRB
'Du
S,
=
TIRB
Lru
DB
T
S,
=3xTIR'
DB
Step Three
Combine the
"A"
and
"B"
dial fbrrnulae solutions
by adding
the
"A"
and
"B"
dials
together
in
a
final formula.
II
S,
=
"tt
xTlR.
+
"rB
xTlR.
'
DA
-
Du
TI
S.
=
":t
vTlR.
-
-tu
xTIR^
-D.\*D"D
The
spindie
shaft
coupling
alignrnent method assumes
all of the rnisalignment
is angular
and will be corrected
at
the
flexible
coupling centrelines.
The
formula uses similar
triangles
to
determine the amount
of
shims required at
Sr
and 32 to bring
the
motor
shaft
centreline
into
alignment
with
the gearbox shaft centreline.
I 60.+03ap3.0.docx
O
2007. Her Malesq
the
Queen
in
right
of
the Province
of
Alberta
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 8/31
Using the
values from Figure
2:
^
60
ri
s,
=-x
)+:x-4=-24mils
'1010
^
90
15
5__x,)+_x 4='2lmrls
10
10
The
values for
S1
and
Sz
from
the combination
"A"
and
"B"
readings
are
the
required
shim moves.
A
positive
answer
means
that shims must be added;
a
negative
answer
means that shims must
be
removed.
A
positive
side-to-side move
means
that
the machine
should
be shimmed to the right-hand side by the value calculated. Always
view the
MTBS frorn
the
fixed rnachine
to determine the
left
and
right
sides.
The amount of
sag
on
the
"A"
and "B" dials
is minimal
as
they
are both
taking face-coupling readings.
Thermal Growth
Thermal
growth
describes small
movements that occur
in
all
types
of
industrial
equipment due to temperature
changes. The temperature
change
within a
machine
causes
the metal to
grow
or
shrink
by
a
fixed
amount that
is linked directly to the coefficient
of
expansion
for that specific metal
(see
Table
1).
Metal
Linear Expansion
per
Unit
Length
per'G
Linear Expansion
per
Unit
Length
per
"F
Aluminum 0.0000223 0.00001244
Brass
0.0000187 0.0000104
Bronze
0.0000'184
0.0000102
Carbon Steel 0.0000114
0.00000633
Cast lron
0.00001
18
0.00000655
Table
1
- Heat
expansion coefficients.
@ 2007, Her Majesq
the
Queen
rn ri,eht of the Province
of Alberta
I 60403ap3.0.docx
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 9/31
The formula
for
deterrnining
thermal
growlh
is the change in length is
equal to the
original length times
the change in temperature
times the coefficient of expansion
for that
parlicular
material.
AL:LoxATxa
Where:
AL:
change in length
(change
of centreline
height)
Lo
:
original length
(distance
from base to
shaft centreline)
AT
:
change
in
temperature
(average
temperature change)
u
:
coefficient ofexpansion
(obtained
from
chart)
Most
expansion
and contraction within machines is due to temperature changes. The
causes ofthese ternperature changes
depend upon the design ofthe machine.
Possible
causes of rise
in
temperature
include adding
heat from steam, heat from compression,
heat
from reaction,
heat
from electrical
load and
possibly
heat from friction
(or
the removal of
heat for the same
reason). Examples of cooler
temperature
machines are refrigeration
pumps,
brine
solution
circulation
pumps
and rl'it.rter
giycol
cooling tower
pumps.
You
must
be able
to
recognize and determine
thermal
growth
problems and be able
to
soive thern.
lf not recognized
and compensated
for, thermal
growth
can
result in shorter
machine life.
Thermal
gror.lth
affects machine
centrelines and therefore tends
to create misalignment
at
the couplings.
Example of
a
Thermal Growth Problem
Given an electric motor driving
a
brine
pump,
create
mathematical
solutions
for
thermal
growth
at
all
shim locations. Use
this information to
create
a
graphical
solution
to the
problem.
Use the values
given
in Figure
3.
.\
Ambient
Temperature
=72"7
Lr
:<
{
}r
L."
L,
I
x'
Figure
3 - Dimensions and
temperature
for
thermal
grou'th
brine
pump
alignment.
X=
10"
|
-
{arr
|
-
Alr
I
-4"
,'-
"^u
Elec{rlc
Molor
MTBS
Ca$on
$teel
-110"F
c
*1oo'r
o
-
so"F
€
r3o"
r
@
120'r
o
110"
r
g
Srine
Purnp
Carbcn Sleel
{*s0"F
s
3o'F
$-*
I
60-103ap3
0.docx
(
2n07. Her Majesn the
Queen
in right ofthe Pror rnce ofAlbena
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 10/31
NOTX
Assume that
the pump
and
motor
were perfectly
aligned when
cold
and not running.
The first
step is to determine
the amount
of thermal
growth
at the 4
shirnming
locations.
You
are
only
concerned
rvith
the thermal
expansion betrveen
the
base and
the
shaft
centreline.
Any expansion
above the shaft
centreline
will
not affect the
shaft alignment.
Tl.re
temperature
of the
components u,'ill
not
be
consistent
from
the
base
to the
shaft
centreline
so
an average
temperature is
required to
be able
to find the
average
thermal
groMh.
The more temperature
readings
that
can be
taken
at the
individual
shim locations
will
result
in a more
accurate
average; four readings is
usually adequate.
A
quick
approxirnation
can be obtained with
only.'
one
temperature reading
taken
at the shaft
centreline.
Add
this temperature to the
ambient temperature
and divide
by trvo. This will
result in
an average ternperature which
assumes that the
base
is at ambient
temperature.
The amount
of thermal
growth
can be calculated in metric
or imperial units,
but because
you usually
shirn
with
irnperial
shirn stock,
you
wiil
calculate the thermal
growth in
thousands
of an
inch
or rnils.
For convenience, round
to the nearest degree
ofternperature and round
to the nearest
thousandth of
an
inch for
shim illoves.
NOTE
You can
perform
these
calculations in metric
or in imperial.
but do not
mix
the
two
systems
when calculating
thermal growth.
Thermal
Growth
at
St
130
+
120
+110
+
90
Average temperature
:
=
I l2.5oF
Round
to
1
13'F
AL:LoxATxa
LL
:24"
x
(l
l3
-
72) x 0.00000633
:
0.006"
The shaft
centreline
will rise
6
rniis at
the S1
location.
Thermal
Growth at
Sz
110+100+90+80
Average telxperature
:
AL:LoxATxu
=
95oF
LL
:
24" x
(95
-
72)
x
0.00000633
:
0.003"
The
shaft centreiine
w'ill
rise
3
mils
at
the S. location.
I
60403ap3.0.docx
aq
2007.
Her Majesn rhe
Queen
in right
of
the
Provrnce of
Albena
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 11/31
Thermal
Growth at 33
9O
+'7)
Average temperature
=
81oF
AL:LoxATxa
LL:24
X
(81
-
72)
X
0.00000633
:0.001"
The shaft centreline
will
rise I mil
at
the S.
location.
Thermal
Growth at St
Averagetemperature
-
3'0
^72
=
5loF
2
AL:LoxATxo
LL
:
24
x
(51
-
72)
x
0.00000633
:
-0.003"
The
shaft
centreline
will shrink or
lower 3 mils at the Sa
location.
The
previous mathematical calculations
predict
the
thermal
growth
of
the
motor.
The
solution
indicates that
the shaft centreline
ra'iil rise up by 0.006"
at the S1 location
and
will rise up by 0.003"
at
the
52
location. Do not remove shims
at these
locations to
compensate
for thermal
grorvth. More information
is needed
before
starting any shirn
rnoves. The thermal changes
to the
purnp must
be
considered and compared to
the
electric
motor
growth
within a
graphical
representation of the
problem.
The
brine
pump
centreline thermal
growth
at the S:
location indicates
a
rise of 0.001" and
a
downward move of 0.003"
at
the
S+
location.
At
this
point.
all of the
necessary
information
is
available
and
requires
analyzing. Construct a
graphical
representation
of
the
problem
and then
analyze
it.
After
constructing the graph, study
it
and develop
some
conclusions
based on the
inforrnation contained
in
the
graph.
It is wise to leave the
pump
bolted
down because moving it could
result
in piping
strain.
Piping strain
is
the
cause
of unwanted distortion of the
pump
housing
due
to improper
pipe
fit-ups. As
the suction and discharge flanges
are
tightened, the
pipes pull
the
pump
housings
out of
shape and
alter the shaft centreline position,
disturbing alignment and
adding internal
stress
to internal rotating
parts.
This is not
good.
Once the
pipes
fit without
strain it is a
good
idea to leave
the
purnp
alone and make adjustments
on the
rnotor.
A
shim rnove under the motor feet is the best solution.
From the
graphical representation
in Figure
4,
one
solution
is
to
have the
/rol motor
centreline
#l and
the
hot
pump
centreline
#2 become one
and the same.
To
accornplish
this,
remove
0.001
" at both
S
1
locations and add
0.006"
shims at both
32 locations.
Keep
in
mind
that this solution
u'il1 only
work
if
the unit
u,as
precisely
aligned
when
cold.
In
other words, the
unit
had to be
precision
aligned
to
within
specs
before atternpting
to
offset the alignment
to compensate for thermal
growth.
Once the offset shim
moves
are
made
on
the
motor it
becomes necessarv to
oredict
u'.hat
the
"A"
and
"B"
dials
read
when
cold and offset.
IS
I 60+0Japj.0. docx
€
2007. Her Ma,iestl the
Queen
in right olthe Province of Alberta
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 12/31
11
C{
l,
T1
ll
il
ll
c0
\
tl
(/,r-=
Figure
4
-
Graph showing required shim move to
align motor to
pump.
160.403ap3.0.docx
O 2007. Her Majest) the
Queen
in right of the Province
of
Albena
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 13/31
NOTE
If
there is
no
sag
"A"
dial
cold should read
-12
mils
TIR
"B"
dial cold
should
read
7
mils
TIR
The
above
readings
for
"A"
and
"B"
dials
are
taken
from
where
line
nurrrber three crosses "A"
and
"B"
dial nlanes.
These
are
TIR
values.
Combination
Misalignment and Thermal
Growth
Correction
It is
possible
to align
a
unit
when
it
is cold and offset
for thermal
growth
by
rnaking only
one set
of
shim moves.
The data in Fisure 5 is used
in
the sample calculations.
Given:
Complete
the Thermal Offset Alignment.
,l
X= 15"
Top
+6
No
Bracket
Sag
Top
0
I e ,/
B\
L.U. , h. t \
t
urar
I
rr
\
unit
)
\3y_/
/T)
Re
\
utit
)
*'
\ggj-l
K.b.
+3
+10
Bottom
Bottom
Figure 5
- Data
given
for thermal
growth
example.
Electric
Motor
(cast
steel)
122',F
156'F
Gear
Box
(cast
iron)
140'F
140"
F
Base
Temp.
is72'F
12
l 60.l0lapl
tt
docr
(
1007. Her N'tajesn the
Queen
in ri-eht
olthe
Province
of Alberta
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 14/31
a at 4 :::::
:a
M:t:
Combination
Problem
Thermal growth
at 51
156
+ 7)
Average
ternperature
2
AL-LoxAtxa
LL:12"
x
(114
-72)x
0.00000633:0
003"
n
.,,
rnotor
t will rise
3
mils at
51
Thermal
growth
at
52
1)) t- 7)
Average
temperature
2
AL:LoxATxo,
AL
-
l2 x(97
-
72)
X
0.00000633:0.002"
rnotor
Q
will
rise 2 rnils
at S,
Thermal
growth
at 53
140
+
72
Averagetemperature-
)
=lU6"F
AL=LoxATxa
AL=
12 x
(106
-72)x
0.00000655:0.003"
The gearbox
Q will
rise
3
rnils at 53
Thermal
growth
at Sa
A'erage
remperarure
:
W
r =
|
o6oF
AL=LoxATxo
LL
=
12" x
(106
-
72) x
0.00000655
:
0.003"
-F
The
gearbox
shafl t
will
rise.i mils
at
Sr
O
2007, Her Ma;esq
the
Queen
in right
of rhr'Province
of
Albena
I 6it403ap3.0.docx
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 15/31
Analyze
the
graph
in
Figure
6 and
determine required
shim moves.
t/J--=
O
Lf)
z--:
O
O|r)
Nrr-r
U)r-=
Figure
6
-
Graph
shon,ing
required
shim
move
to align motor
to
gearbox.
\
c\l
u
U)
-i-
ll
:
f.*
ll
-
{(t")
-)[.C)[N]OrOr-
c)
o
-
l-l-:-:'
-,u
: :]
d]
\OE
\ 99
\,-r1--
\
cJt
'
to&-:
,
vE
--.98-
\c\
1
{Jt--
t'O$
-
-1
9N-
.'
tv[
\oN.
lal
l"
IX
i.Y
iCI
te
l'1-
L
:::]U
..i....:...:.i
x
-i-a-li
^
o
.c
J
l€
ln*
l*
E
o
6ii
(Jir
...i og.
\.2\
\6&
r:L>
,:,]...,
....izN,
lct
to\
lS4
i
':.
:.'...:..:$
i..i..:.r
r
"S
....tr \
:--i-:':
-, '-r f.--a-:-n-\-..
...1....i.-.
.'...'i...i.- l
-i.^i
.li-.i*ii-i--
i&
I-
:.N
I
d
r
-r
--
r^-l(-)
LO
tl
cv
C7:
'=
=\
-:.^
,-
c*
(,ll
5m
}
*f
i
_ ertt
-
t&l
\\
r.i f-
:il
F
ir,,..
\
{
4
tJt
lrl
tvl
ra ,
rn
i
E
a.
*.'T
*
l-J--t"r.i
s-i
_s
:*T
t4
I 60403api.0.docx
O
2007. Her Majestl
the
Queen
in right of the Province of Alberta
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 16/31
From
the
graph in Figure
6,
you
can see that
the
gearbox
raises
up
0.003"
at
the
53
and Sa
locations; leave
the
gearbox
bolted down. The hot gearbox
centreline is represented
by
line 2. Linel represents
the original cold rnisalignment
present
at
the
coupling. Line
3 is
the hot motor
centreline. In other words, the motor moved frorn
line
1
up to line
3
when it
was started and
loaded. Line
3 shows
a
fair
degree
of angular misalignment
of the hot
motor centreline
as
compared
to line
2,
which
represents
the hot gearbox centreline.
To correct this misaligrunent
of
the motor,
0.003" shim
removal
is required at
both S1
locations
and 0.001
inch
shim
addition
is
required
at
S:
locations.
These
shim adjustments
lower the drive end of the motor and raise the non-drive end enough
so
the centrelines of
the
motor hot
and
the centreline of the
gearbox
hot
are
common.
This section
helps
you
determine what the dials should
read when
the correct shim
adjustments
are completed. Line
4 represents
the cold
motor offset centreline. To
establish
the
S1
position for line
4,
subtract or
remove 0.003" shims
from the intersection
of
the
line 1 and S
r
plane.
To establish
the
52
position for line
4, add 0.00
I
"to the
intersection
of the
line 1
and
Sz
plane.
Where line
(4)
crosses A and B dial
planes,
these
values
indicate
that the correct
dial reading for
the cold offset
motor A dial reads'0.002"
TIR
and
dial B
reads
-0.00025".
The
previous
example
is
a
guideline
to show
you
how to align
a
motor to
a
gearbox
cold,
taking
into account
the thennal
growth
of both units and
the amount
of original
misalignment
present.
Once the
alignment is complete
it must be confirmed by
some
feedback loops.
First, the cold offset
rnisaligned machines
result in
dial
readings that are
not
zeros.
The readings expected
are
predicted
from line 4 where line
4
crosses the
A
and
B dial
plane
lines. Secondly, upon stafi-up the
unit vibration
should be
a little high until
the
motor and the
gearbox
reach operating temperatures.
At
this
point
very low
acceptable vibration
readings indicate
*'hether
the
procedure
is
successful.
lfthe
vibration
level
continues
to increase
to
higher levels after start-up, it is
safe
to conclude
that the
procedure u'as not
successful and the unit
must
be
realigned
and
rechecked
for
mechanical integrity.
Mechanical
integrity is a term that describes the
mechanical condition of
a
machine.
Good mechanical
integrity
means that the machine is
in
excellent
condition;
poor
integrity means
that
the machine has
a
number of mechanical faults.
Hot Alignment
Methods
Hot
alignment
is
a
tenn that describes
a
number
of ways of checking
the alignment
of
one
or more
shafts
in relationship
to each other
once the rnachines have
been
put
online
(started
and
loaded)
and
a
thennal equilibrium has
been
reached.
Thermal equilibrium
means
that
the machine
has reached
its ruming temperature throughout
and
no more
heating or cooling
will
take
place. In
other
words, the
unit has reached an operating
temperature
throughout
and there
will
be
no more metal
thermal
growth.
1 60403ap3.0.docx
O 2007. Her Majestl'the
Queen
in right of the Province of Albena
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 17/31
."
;
lf
The quick
hot alignmenr check is a very
poor
method
that
can
give
enoneous results. This
is
because the hot running unit is shut down,
isolated and
prepared
for
a conventional dial
or laser
procedure.
This
method is
poor
for the following
reasons.
e
Shutdowns
are
costly
and unpopular
with
operating
personnel.
.
The equipment cools down
very
quickly,
which
results in ever-changing
alignment readings.
r
The
media
that had been flowing through the machine
stops
flowing; as a
result,
hydraulic
effects
cease
and
moments
of force are eliminated.
.
Couplings sornetimes
have
to be disconnected, u'hich this takes up valuable
time.
o
Close
proximity
to high temperature
casings
can result in
burns to
personnel.
The
traditional
hot alignment method is not reliable and rarely works.
Online
Hot
Alignment
Checks
Online
hot
alignment
means
that
you
can
track the
alignment changes
of two or more
shafts
in relation to
each other by some
specific
procedures.
The
procedures
do
not
require the
unit
to be unloaded
or shut dorvn.
The
procedures require some
permanent
measuring devices to
be
mounted
on
the machines being
monitored.
The most common
methods
are
the
optical
tool method,
the laser beam and
target method,
water
stand
and
proximity
probes,
Dodd's bars
and transducers and
the Essinger tooling
ball method.
All
of these
methods
provide reliable online
alignment
data. The methods
vary
greatly in
cost,
complexity
and ease of
use.
None of the
rnethods are applicable to every situation.
Review the
rnerits
ofeach
system and choose the
system
that
best
fits the
need.
Precaution
With the exception of instrumented couplings, all of the
methods listed
belorv use cold
coupling alignment
readings
as
baseline
from
which
to
calculate
(or
plot)
hot
coupling
aiignment.
An instrumented coupling has alignment
probes
built
into
the coupling.
Regardless of the
method
used,
it is vital that the cold baseline
data be taken
at
the same
tirne
the
cold coupling alignment
data
is
taken-
For example,
reliable results cannot be obtained by taking coupling data
in
the cool of
the
morning
and
hot
alignment baseline data in the blazing afternoon
sunshine.
Take
the data
sirnultaneouslv.
I
604tljapi.0.docx
O 2007. Her Majest]'the
Queen
rn right
of
the
Province
of
Alberta
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 18/31
Optical Methods of Determining
Machine Movements
Optical methods
(Figure
7) use very
precise
surveying techniques
to determine
machine
movements,
from which shaft
alignment
information can
be obtained.
To use the
optical
method,
the coupling alignment is
performed
in
a
conventional manner.
Once the alignment
is satisfactory, the
vertical
and
horizontal
baseline
data are
obtained
with
the aid
of
precision
levels and transits.
'fhis
baseline data
is taken
off
flat-machined split
joint
surfaces.
When the equipment is
put
online
and brought
to equilibrium.
this same
optical
instrumentation is used to detennine the movement of each of the machines
with
respect to
the baseline data.
From this data.
runnins
alisnment can
be
plotted
or calculated.
.
Cold alignment
is
the benchmark.
.
Movement
is referenced
to line af sight.
.
Optical
levels and
jig
transits are
used
to determine
vefical and
horizontal
machine
movements.
Figure 7
-
Hot check by
optical
means.
Some companies
employ
in-house specialists
to
conduct hot alignment
checks by
optical
methods
and some
use one of the several
commercial firms
rvho
offer
these services.
Lasers
Several variations of
laser rnonitoring
(Figure
8) are available. Machines
are
ty'pically aligned
in
a
conventional
manner using dial indicators
or lasers;
another
laser/reflector system
is
used
to
rnonitor
the movement
of
one
machine casing
with
respect
to the adjacent casing.
.
Cold alignment
is
the benclrmark.
.
Laser system is
used
to
monitor
relat:ve
machine movemenls.
.
Data
is analyzed and
recorded
by computer system.
Figure
8
-
Hot check
by
laser
systems.
From
this data,
coupling alignment can be
determined
by
plotting
or
by
calculations.
In
some systems, the
laser equipment is mounted
perrnanently
upon the equipment.
In
other
systems, brackets are
used
to
permit
the lasers to
be
installed
and/or
removed
during
operation.
I 60.103ap3.0.docr
ic-
2007.
Her Majesq the
Queen
in right of the
Prorince of
Albena
It
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 19/31
Proximity
Probes
with
Water-Cooled
Sfands
With
this method
(Figure
9), water-cooled
stands are attached
to the
foundation
near
the
couplings
and outboard
bearing
housings.
These
stands are
support electronic proxirnity
probes,
which
monitor
the movement
of the coupling,
shafts
and/or
machine
casings
relative
to
the foundation.
.
Cold
alignment
is
the
benchmark.
.
Machine movements
are referenced
to water
cooled
stands.
.
Prcximiiy
probes
detect
machine
movements;
data is monitored
and/or
recorded.
Figure
9
-
Hot
check by water-cooled stands and
proximity probes.
With the above method, coupling alignment is done
as
per
norrnal
plant
standards,
at
which time baseline
proximity probe
readings
are taken. Equipment movements
are
monitored via these
probes
as
the
equipment
is
brought online and comes to equilibrium.
While the machines
are
changing alignment
due
to
increases
in
operating temperatures,
the readings
given
by the
probes
are monitored and recorded. Movenrent
of the
equipment
relatit,e
to the
proximity probes provides
data
from rvhich
to determine
running
aligrunent
of the equipment.
Dynalign
(Dodd)
Bars
This method
(Figure
l0)
of continuous. online
monitoring
uses
proximitl'
probes
fastened
to
pemanently
rnounted
brackets on the
coupled machines.
The brackets
are arranged
in
a
fashion
sirnilar to that ofindicator
brackets
used
in
the
reverse
alignntent ntethod,
except
that the brackets
are
mounted to
the
housings, not the shafts.
Vertical
and
horizontal
dara
from four
probes
supply
information
about the relative movement
of the machine
casings.
Figure
10
-
.
Cold
alignment rs
the benchmark.
.
Relaiive
machine movements are referenced
to bars
affixed
to opposite
machine.
.
Proximity probes
detecl
machine movements;
dala is monilored
and,lor
recorded.
Hot
check by Dynalign
(Dodd)
bars.
With
this method, cold
alignurent is done in
the
as
per plant
standards and baseline
data
is
read
off
the
probes.
Output from
the
probes
is
then monitored
and/or recorded. Data
is
sufficient
to
plot graphically,
calculate
mathematically,
or
indicate
where
the equiprnent
has
moved
during
thermal
growth
changes
C.W.
18
I burlUiapi.0.docx
e,2007.
Her
Majesb,the
Queen
in righr
ofthe Province
ofAlberra
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 20/31
Benchmark
Gauges
(Acculign
Sfeet Tooling
Ball
Method)
This
systern (Figure
I 1)
monitors the
movement
of bearing
housings
or machine
casings
with
respect
to
the equipment
foundation.
With this system, permanent
benchmarks
are
mounted
on the equipment
and the foundation.
Once
the
n.rachine
is aligned,
benchmark
gauges
are
used to detertnine
baseline
measurements
between
the
foundation-mounted
benchmarks
and those
mounted
on
the equipment.
when
the
machines
are
brought
online, benchmark gauge
readings
are
again taken to detennine
the relative
movement
of
the equipment.
.
Cold alignment
is
the
benchmark.
,
lVlachine movements
are referenced
to foundation.
.
Movernents are measured bv dioital
benchmark
gauge.
.
Alignment analyzed by PC
program.
Figure
11 -
Hot
check by benchmark
gauges.
Running
alignment of
the
coupling is
normally calculated
by a
personal
cornputer
(PC)
software
program,
but
can
also be detennined
by
graphical
methods.
Instrumented
Cou
plings
Instrumented
coupling
system
(Figure
12) electronic
probes
are
built into
the couplirrg
spacer.
Power
is supplied
to the
probes
by
a
stationary
transformer. The
signals from
the
probes
are
retrieved in
a
similar
manner.
This
arrangement
provides
online,
continuous
monitoring
of coupling alignment
as
well
as axial movement
of the coupled
shafts.
'
Base
data is
by coupling
caljbration.
,
Proxinrity
probes
within
the
coupling
detect misalignment.
.
Signals
and
power
are transmitted
by stationary transformer.
Figure
12
-Hot
check
by
instrumented
couplings.
dffirh
IJ:
W
1 60.103ap3 0.docx
io 1007.
Her Majesq the
Queen
in rrght
of the Provrnce
of Alberta
19
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 21/31
Satisfactory
and
long-lasting
alignment is
achieved
by
paying
attention
to details
throughout
the design, fabrication
and installation
of the
equipment. The
following
are
minimal
requirements:
o
rotating
equipment
that is
properly
designed
and
well-made,
a
well-designed
and
properly
executed
system
into which
the equipment
is
integrated
(this
rneans
choosing
the right
online monitoring
equipment
and
installing
it
according
to suggested
engineering
specifications),
knowledgeable,
careful and
experienced
craftsmen,
proper
training
of craftsrnen
and supervisory personnel,
appropriate tools,
standards
and/or specifications
detailing alignment
requirements
and
a
system to
assure
that
job
specifications
are
followed.
Characteristics
of
Online Monitoring
AIJ online
monitoring
methods require
a cold
accurate aligmnent to be
performed
initiaily
before
installing special online monitoring devices. The initial cold aligrunent
gives
the
necessary
reference
measurements needed betu,een
the machine shafts
and the
instruments.
Most online
methods are
very
susceptibie
to
unwanted accidental instrument
movement. For
example, the optical
system requires
the
precise
iocation
of
the telescope
on
a
tripod or base.
lf
the base is not
protected
by
a
house
with
windows the tripod may
be accidentally moved.
The result is
that all the readings are inaccurate and the
procedure
must start over
from
the initial cold alignment start
point.
Lasers are also vulnerable to
accidental external movements
of
stationary
pennanent
mounts. The
permanent
mounts
must
be of
rigid
design
with little
or
no
thermal
growth.
Water-cooled units made from
titanium
or
Invar
(high
nickel steel) are
the
preferred
types.
Proxirnity
probes
are fitted to special
constant temperature water-cooled
stands
that
are
secured
to the
same base. The danger or downside
ofthese
stands
is
that they are very
susceptible to accidental movement from
external forces,
such
as
personnel
contacting
them. Over tirne, vibration can
cause
mechanicai
looseness
because
of
cracks
in
the
stand.
Another
problern
that can cause all reference measurements
to be lost is
a
rvorker who
unknowingly removes the
stands
while
making a repair.
After
the repair is completed
the
stand
is
reattached
to the rnachine,
but all reference
rneasurements
are lost
because the
stand is mounted
in
a
slightly different location.
Dynalign
or
(Dodd)
bars are susceptible
to cracks
due to
vibration after
a
period
of time.
Once a crack develops,
all
the reference
lneasurements
are lost and
the online monitoring
gives
false information.
Benchmark
gauges
are also susceptible
to
accidental
external
forces
and
shifts
or cracks
in
the
foundation.
One
industry
standard used
to
check
multiple
machine
coupling alignment
is
the
machine
tooling ball
(benctmark
system), which is an online
mounting
system.
It
is
very reliable
and relatively easy to
use.
The next
section deals
with
this
system.
a
a
a
a
a
2&
I
60+0iapj.().docx
.e
2007. Her
Majesq the
Queen
in right
ofthe Province
ofAlberta
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 22/31
Online
Monitoring
of Coupling
Alignment
Benchrnark gauges
are
used to take
very accurate
measurements
between matching
sets
of benchmarks.
The
benchmarks are
stainless steel
8
-
18
metal
that has been
machined
to form
a ball
on one end rvith
some type
of
fastener
on the
other
end. These
benchmarks
are mounted
permanently
to the machine
and
the rnachine
base
so
that
measurements
can
be
taken between the balls at
any
tirne
desired.
Common
Styles
of
Benchmarks
Common
styles of benchmarks
are
discussed
in this
section.
Weld-On
Benchmarks
Figure
13 is
an
example
of a
rveld-on
benchmark. This benchmark is
on
a
fla non-
threaded
base
that is welded
directly
to the equiprnent and has the same 95o useful limits
as other benchmarks. The
base
is
'/a
inch in diameter. The measurement from
the
base
to
centreline of the ball is
3
inch.
Useful Limits in
Which
Figure l3
- A weld-on benchmark.
Threaded Benchmarks
Figure
14
is
a
simple
benchmark that is useful
for a wide
range
of non-critical
applications that do not require the
long-term protection
afforded
by
other benchmarks.
A
threaded
benchmark
is
a
one-piece construction
of 18
-
8 stainless steel and is
screwed
into
a
tapped hole and secured with a locknut. The stainless steel locknut is fumished
with the unit.
k
.:
(,,Q'l
l.
I
J/O
t
Usefui Limils
in Which
to
I
Use Benchnark Gauge ----J
3/B-16 NC
(remov*ble
locknut)
Figure
14
- Threaded benchmark.
I 60.103ap3.0.docr
@
2007.
Her
Majesr,v-
the
Queen
in right of the Province
of Alberta
zl
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 23/31
Covered
Benchmarks
Covered benchmarks
(Figure
1,5)
are recommended
for
general
turbo
machinery rvork
(turbine-related
equipment). These are
one-piece
construction oftype
l8
-
8 stainless
steel
and
are
furnished with
a
%"
x l6 NC
carbon
steel
stud
for mounting
directly into a
tapped
hole.
Altematively.
the
stud
can be removed
for mounting directly
on
a
'.{"
x
l6
NC male thread,
or the base
of
the benchmark
can be
welded
directly to
the equipment.
If
threaded fasteners
are used. it is
recornrnended
that the
assernbly
be
bonded
in
place rvith
epoxy
to
avoid inadvertent
movement. The
protective
cover
is nrade
of moulded plastic,
rvlrich
offers
good
mechanical ploperties
and excellent
corrosion
resistance.
To mount
this benchmark
in
concrete,
use
a
benchrnark
mount suclr
as
that shown
in
Figure
16.
Properly tnounted,
this
protected,
stainless
steel benchmark affords alignment
reference
for
the
life of the
equiprnent.
3iB
-
16 NC
Uselul
Limits
in
Which to
,/
-i
use Benchm6lla $6uqg
-----l
Figure 15
-
Covered
benchmark.
Benchmark
Mounts
Benchmark mounts
(Figure
16)
provide
an excellent rneans
of mounting
covered
benchrnarks to concrete or lnasonry structures
or
foundations. The
units include a
concrete
anchor,
'11"
-
16 NC
stud,
and a heavy rnounting
ll'asher.
This mount
is installed
in
a5l3
inch
diameterby
2tla
inch
deep
hole.
Epoxy
cement
rnay be
applied upon
assemblv
to
enhance
rnechanical intesritv. The benchmark
is
not
included.
318-16 NC
$tud
2118"
Figure
l6
-
Benchmark
mount.
--r--
-
3/8
I
i
t
l
I1/4"
"k
I
t\
l;-
[-
23,'o"
to
Rerrrove Cap
tt
I 60.+()iap-i.0.doc\
C 2007. Her Majesry
the
Queen
in righr of il:e Province of Albena
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 24/31
Masonry
Benchmarks
The masonry
benchmark
in
Figure
17
is made
with
a
o/ro
inch
diarneter
base
which can be
bonded
by epoxy directly into a'l3 inch
diameterby |
'la
deep hole.
This
is
especially
useful for non-critical
applications
requiring
placement
of
benchmarks in concrete.
It is
made of one-piece
construction of type l8
-
8 stainless steel and
has
the same 95o useful
limits
as
other benchrnarks. The dimension
from
the
base
to the centreline
of
the
ball
is
I
-/a
lnCh.
,-)n
Useful Limits in Which
to
,
?5'
use Benchmark Gauge
*--,/
|
Epoxy
.(9/16',:
Figure
17 -
Masonry benchmark.
Benchmark Protectors
Benchrnark
protectors (Figure
18)
are recommended
for use
u'hen the
benchmark must
be
placed
in
a
location in which
it
is
subject to mechanical damage. These
protectors
are
made
of
galvanized pipefittings
and
come complete
with four
concrete anchors and
screws
for mounting. Anchors
require holes '/z
inch diameterby
I'la
inch
deep.
The
benchmark is
accessible
by unscrewing the
cap and
pipe nipple. The floor flange need not
be
removed to take benchmark
gauge
readings.
Dimensions
are approximi
Mounts with fcur concrete
anchors
(furnished}.
d g
a.)
A1/'\
q/2
Figure l8 - Benchmark
protector.
I
60403ap3.0.docx
O 2007, Her Majes4
the
Queen
in
rjght of the Province
of
Alberta
,3
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 25/31
11'
NOTE
Once
benchmarks have been
mounted in
strategic locations
they
should
be
protected
from
external forces
that can move
the ball.
Mounting Benchmarks
Mount all benchmarks
as close as
possible
to the shimming
planes,
as
shown in
Figure
19.
Figure l9
- Showing
end views of the benchmarks and
gauges installed.
NOTE
Benchmark
gauges
are only used for
a short time to take accurate
readings
and then they are stored in their wooden
cases.
60'Mininr*m
12S"
fiirim*m
9C*
L.4inin:um
S*"
tu'linimunt
"120.
l,4inimum
?il'
I'n4inirrun't
.i,
I 60.103ap3.0.docx
O 2007. Her Majest)'the
Queen
rn right
ofthe
Province
ofAlberta
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 26/31
I
Basic Benchmark
Gauge
Set
(ltem
1M for Metric
Units)
Benchmark
gauges (Figure
20)
are specifically designed for
conducting
online checks for
turbine-related alignment.
The basic
benchmark
gauge
set
consists
of a telescoping
column with an electronic
dieital readout.
six extensions. a 25-inch
(625-mm)
standard
and an
inclinometer.
Indicator
Tooling
Ball
Spring Lcaded
Telescoping
Sleeve
Dial
lndicator
Mounted
in Bar Assembly
Standard
Inclinometer
to
Measure
Bar
Angle
Essinger Bar
Kit
Figure 20 - Essinger benchmark
gauges.
The
benchmark
gauge
is spring-loaded
with spherical
seats
at
either end to match
the
spherical benchmarks
that
are
mounted
on the equipment. The
gauge
is self-supporting
when placed
between
pairs
of benchmarks.
The range of the
benchmark
gauge,
u,ithout
extensions, is 25 inches
to 30 inches
(625
mm
to 750 mm).
The six extensions
give
the
tool a
range
of
25 inches to 60 inches
(625
mm to
1500 rnm) in increments of 0.001 inch
(0.01
mrn). The
standard
and the extensions
are
constructed
of lnvar. The low coefficient
of thermal
expansion of this material
greatly
reduces
measure[lent
errors
resulting from thermal
expansion
of
the
tool.
The
standard
and the extensions are
manufactured to
an
overall accuracy of 0.001
inch
(0.025
mm) in
length.
The exposed
portions
of
the
tool, including
spherical
seats,
are made of stainless steel.
,r,...
f,t
Essinger
Bar
$et
Up
.,Fd1
,
*try
"
"='tt'S
uy\
lnclinonreter
#
df
O 2007, Her Majes4'the
Queen
in flght
of the
Province
of Alberta
160403ap3 0.doc>;
:=
25
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 27/31
Working
Example
of
Benchmark Procedure
Align
the machine to
a
high
degree of accuracy.
The
machine must be locked out
(not
running or turning over) and must be of
ambient temperature.
Once the
machine is aligned,
fasten
the
benchmarks to the machine and
the
base.
as
close
as
possible
to all shimrning
planes.
It becomes
difficult
to mount the
balls
so the included
angle
between the
base
and the benchrnark
gauge
is 45o. Oil lines, instrument
gauges
and
other equipment
sometimes
get mounted
in
the benchrnark
tool
pathway,
which forces
you
to
choose
a slightly different angle
of approach. This nerv
angle
may
require
installing new tooling balls in the base
or on the machine
housing.
If
bearing
housings are
readily
accessible, benchmarks
are
located as in
Figure
2lA.
Where
they are
not readily accessible,
an alternate such
as
that shown
in Figure
21B
may
have to be used.
Figure
21 - Benchmark
procedures.
The
benchmarks
can be
attached
to the
machine by drilling and tapping
holes in the
machine bearing
housings. The
fasteners screrved
into
the
drilled
and tapped
holes should
be installed
with a
permanent
thread-locking
compound
so
they do not
vibrate
loose.
The
benchmarks rnounted
in
the
base
may
be
cemented
in.
bonded
in rvith
epoxv.
or
welded
or
threaded to
the
base
structural steel.
All of the benchmarks should
be
protected from
external
accidental contact,
which can
bend or
distort them and
change the benchmark
gauge reading.
Using
an electrical or rnechanical benchmark
gauge,
measure
the
distances betu,een
pairs
of benchmarks. The angles and
measurernent
readings
are
taken and recorded for each
position.
The benchmark
gauge
set includes an
inclinorneter,
which uses a
pendulum
to
fileasure the benchmark
gauge
angles
in
relationship
to
level
base.
NOTE
Remember that
an
acceptable
cold alignment
must
be
completed
first.
B.
.
to
1
60.103ap3.0
docx
@
2007. Her
Majesq'the
Queen
in right of
the
Province
of
Alberta
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 28/31
i;ri:
.,;:
:,
l1r1
Lt\
l
Self-Test
1.
Why
misalign
a
set
of
machines
at the coupling rvhen perforrning
an
alignment?
a) to
be
within
coupling specifications
b) to account for coupling
wear
c)
to offset
for
thermal
growth
d)
to correct for
seasonal
foundation
mover.nents
2.
Is
it
possible
for two
coupled rnachine shafts to share
a common centreline in
the
vertical
and
horizontal
nlanes?
a)
yes
b)
no
3.
If
a motor
and
pump
have
a vertical
mount
(shafts
up and
down, not horizontal) do
they require
precision
alignment,
like horizontal units?
a)
yes
b) no
1.
lncreases in ternperature
and pressure cause
a
rnachine shaft
to
change
its
position
slightly.
a) true
b)
false
5.
What is
a
moment
of
force
caused
by
a
flowing media?
a) A
force
generated
in
the same
direction as
the
flowing
media.
b) A force
on
the
housing
generated
in the same direction as the
media travel.
c)
A hydraulic
force caused by
pressure
pulsation.
d)
The windage force created at the coupling.
6.
ls it possible to
predict
accurate
A
and B
cross dial sweep
readings
once the rrachine
has
been offset
for
thermal srowth?
a)
yes
b)
no
7.
What
is
the
value
of the
information collected when
you perform
a hot aligmnent
check?
a) It
deterrnines machine
foundation integrity.
b) It
indicates
soft
foot
conditions.
c) It reveals improper
coupling
spacing.
d) lt
reveals relative
shaft
positions.
8.
When
shafts
are
not
aligned
u,ith
each
other in the vertical and horizontal
planes
when running.
what
is the most
corlmon
result or syrnptom?
a) Bearings develop
oil whirl.
b)
Bearings wear
until
they
align
themselves.
c)
Vibration levels
increase.
d) Alignment
nleasurements
change.
U
U
I 60:+03api.0.docx
@
2007. Her Majest]
the
Queen
rn right
of the
Province
olAlberta
U
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 29/31
a:a::,a.:aaa:::::.a.a:::,::.
tt :
:i'' I ::rl:i::::,:::ii:l ll::
9. Why must
you
acquire
a safe work
permit
after receiving an
alignment orientated
u'ork
order?
a) Management requires it.
b) OH&S
requires
a
copy.
c) You require it for
your
records.
d)
It
is
a
requirement
for
personnel
safety.
10. The
purpose
of a millwright racking
out
a
breaker
rvithin
the local M.C.C.
before
performing
an alignment is:
a) to
prevent
rnachine
shaft
rotational
drift.
b) to
prevent
machine
shaft
rotation.
c) to
prevent
accidental starts/runs.
d) to
prevent
breaker
contact arcing.
1
1. Why must all energy sources
connected
to
a
machine be blocked
off,
locked and
tagged before
alignments are
commenced?
a) to
prevent
uncontroiled
process media
from flowing
b)
to
prevent
unskilled
workers
from being trapped
inside
c)
to
prevent unusual sequence
ofalignment
events
d)
to
prevent
an
unwanted
high-speed
roilover, either
foru'ard or ret'erse
12. The
procedure
to
chain some
valves in the closed
position
is required before
perfonning
an alignment
(assume
the valves are
chained. locked
and
tagged).
Why?
a)
It
gives you peace
of
mind.
b)
lt
protects
fellow
u,orkers.
c) It
prevents
energy
flowing.
d) lt
is a
form oflockout
safety
required.
13. After locking out a breaker at the M.C.C.
and
placing
the information tag
on the
lockout device, what should
you
do at the machine before commencing with
a
coupling
alignment?
a)
Check that all tools are
available.
b) Remove
the coupling
guard.
c)
Rope
offthe area.
d)
Try the local cornmand station.
14.
To align
a
turbo compressor
you
must have
the stearr lines blocked and
bled off as
well as having the valves
chained, closed and locked.
Should dynamic
compressor
piping
also be isolated and
bled offand locked out?
a) No. it is not necessary.
b) Dynarnic units
isolate
autornatically.
c)
The compressor state does
not matter.
d)
Yes,
it
should
be done because
backflows energize
the unit.
15. When aligning
an electric
motor to
a
hydraulic
pump
the system including the
accumulators
should be
bled off
and then
isolated because:
a)
an increase in temperature could cause the
pressure
safety to open.
b) high-pressure trapped oil could backflou'through the
pump.
c)
other components in the system
rnight
be
energized.
d) no system
pressure
is required.
160403ap3 0.docx
O 2007, Her
Majest)
the
Queen
in right ofthe
Province
ofAlbena
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 30/31
16.
What
can happen
to millwrights
perforrning
shaft aiignment
on
a
pump
if
accidental
reverse
flow
ofoil
through
a
hydraulic
system
occurs?
a) Nothing
will happen
because
there is no
shaft
movement.
b)
The
pump
rnight
run forrvard
and injure
them.
c)
The
purnp
might motor
backwards
and injure
thern.
d)
The
dial
brackets
and
alignment
tools
attached
to the
shafts can
catch on
clothing
and injure
the
worker
if the pump
motors
backwards.
1 7.
Lasers
can cause
serious
eye injury due
to:
a)
direct viewing.
b)
indirect
viewing.
c)
amplification
through
targets.
d)
flashes
caused by dust
parlicles.
18.
What is meant by
bucking in alaser unit mounted
on
a
rnachine?
a) It
is
a
laser self-check for
accuracy.
b) It is mounting the laser
bearn
centrally within
the
base.
c)
It
is
a
method
used to check the machine
housing for accuracy.
d)
It
is setting the
laser
to
a
benchmark location.
19.
Do
laser
beam targets hat,e a
set
of direct mechanical
microrneters?
a) No, they
are
not necessary.
b)
Yes,
they
alu'ays require
checking by constant feedback.
c)
Yes,
because laser beams can fail.
d) Yes,
because lasers
are not self-centring.
20.
Do laser
beams sag due
to
gravity?
a)
yes
b)
no
21.
Drive shaft
coupling
alignment
can
be used to check:
a)
drive
shatls
for
straightness.
b) u'ear in the
couplings.
c)
alignment of the motor
shaft to the
gearbox
shaft.
d)
degree ofshaft levelness.
22. Drive
shaft
(or
spindle
shaft)
alignment
uses
two dials
mounted:
a)
one
inboard
and one
outboard.
b)
one on the
rim
inboard.
the
other
on the face
inboard.
c)
both on the rims,
one inboard
and
one outboard.
d) both
on the
same
plane,
one inboard,
one outboard,
both on the
face.
23. When
using the formulae
to
calculate the required
shim moves
for a spindle
shaft, a
positive
value means that
shims should be:
a)
removed.
b) added.
24. What is
the
purpose
of
online coupiing monitors?
a)
to align shafts
when cold
b) to
align shafts when
hot
c)
to
provide
a
quick
hot alignment
check
d) to check
alignment
while
the machines
are
running
U
U
48
@
2007,
Her Majesq'
the
Queen
rn nght
ofthe Province
ofAlberta
v
I
60403ap3.0.docx
8/19/2019 Advanced Alignment Alberta Module
http://slidepdf.com/reader/full/advanced-alignment-alberta-module 31/31
Self-Test Answers
1.
c) to offset for
thermal
gron'th
2.
a)
yes
3. a)
yes
4.
a) true
5. b)
A
force
on the housing
generated
in
the same direction
as
the media
travel.
6. a)
yes
7. d) It reveals relative shaft
positions.
8. c) Vibration levels
increase.
9. d) It
is
a
requirement
for
personnel
safety.
10.
c)
to
prevent
accidental starts/runs.
I
1. d) to
prevent
an
unr.l,'anted
high-speed rollover, either
foru'ard
or
reverse
12. d) lt is
a
form
ofiockout
safety required.
13.
d)
Try
the
local
command station.
14.
d)
Yes,
it
should be
done because
backflows
energize
the
unit.
I 5.
b)
high-pressure trapped
oil
could backflow
through the
pump.
16. d) The dial brackets and alignment tools
attached to the
shifts can catch
on clothing and injure the worker if the
pump
motors backwards.
fi. a) direct viewing.
18. b) It is mounting the
laser beam
centrally
u,ithin
the
base.
19.
b)
Yes, they always require checking by constant
feedback
20.
b)
no
21
. c) alignment of the
motor
shaft to the
gearbox
shaft.
22.
d)
both on the
same
plane,
one inboard,
one
outboard, both
on
the
face.
23. b) add
24.
d) to check
alignment while
the machines
are
running
1 60403ap3.0.docx
49