Article Summary:

Alignment tolerances have been treated in the past with an 'Oh, by the way...' or 'Just get it
close...' attitude. Where in fact, they are the measurement of a job well done and a definition
of what 'close' actually is. The intention of this paper is to describe how to define tolerances
in a generic manner and explain why they are useful. This includes: What is offset and angle
and why should tolerances be specified this way as opposed to total indicator runout (TIR)?
What are jackshaft tolerances and when should this type of tolerance be used? and Can
alignment
tolerances
be
standardized?
INTRODUCTION
Here is the common scenario, at 7:45 a.m.:
Front Line Foreman: "Here is work order number WJ-3487 for process pump PU-12A. We
had to buy a new motor. The old one was shot. Funny I think it only lasted a couple of
years...anyway, it needs to be aligned."
Mechanic A: " How close do you want it?"
Front Line Foreman: "Production needs it back on line by this morning at 10:00."
Mechanic A: "I don't know if I can get finished by then."
Front Line Foreman: "Just do the best you can."

By the time the tools are gathered and the machine is properly locked out, it is 9:00 a.m. In a
hurry to take at least one set of readings it was decided (guessed) that this machine had no
runout or soft foot problems. Machine moves were quickly made and the second move
required that the motor inboard had to be dropped by 30 mils and the outboard by 90.
Equivalent to 5.0 mil/inch angle and 7.0 mil offset in this case. No shims were left under the
motor. By this time it is 9:40 a.m.
Mechanic B: "How close are we supposed to get it?"
Mechanic A: "Well, Production wants it back at 10."
Mechanic B: "Allll righty then....time to button it up."

Figure 1 -- Likely Results

In this case, time drove the alignment job. Unfortunately, limited time does not lend itself
toward a quality alignment. I am not saying to put no time limitations on the job, just allow
enough to perform all the things required to perform a quality alignment. Those things

include, but are not limited to: soft foot correction, correction of bolt-bound conditions,
removal of runout, etc.
WHY USE TOLERANCES
Not bragging or anything, but if I was given the proper chance, I could beat Howard Hill,
world champion archer, at his own game. No, I am not anything to write home about when it
comes to archery. But if I were to blindfold Howard Hill, spin him around several times, give
him the bow and arrow and then set up the target. He would have a very difficult time hitting
the bull's eye since he would not know where or what he is shooting for. To be successful he
needs to know where the bull's eye is, or in other words, the goal.

Figure 2 -- Establish a Bull's Eye

This is essentially what happens when a mechanic goes to align a machine and has no idea of
when the job is complete. Missing the bull's eye in this case means more than losing an
archery championship, it means pouring money down the drain. The main reason to use
tolerances to establish goals. Without a goal, a quality alignment will not be performed.
Another benefit from established tolerances is accountability. Accountability is the evaluation
or monitoring of alignment quality. If no tolerances exist to be compared to, then
accountability does not exist. This accountability can even create competition among the
mechanics. How often have you heard, "We got it within 2 mils?" Competition is good. It will
drive the mechanic (with the proper attitude) to get the job performed better, even though it
may be in the 'acceptable' range already.
MISALIGNMENT TYPES
Before the tolerances can be discussed, the types of misalignment must be explained. Shaft
centerline misalignment can be categorized as either offset (also referred to as parallel) or
angular. The following figure shows examples of both types.

Figure 3 -- Types of Misalignment

Angular misalignment occurs when the shaft centerlines meet at an angle. Offset occurs when
the shaft centerlines are parallel but are offset from each other. Misalignment is normally a
combination of both types.
In a close coupled application, offset is typically measured at the center of the coupling and is
usually expressed in mils (thousands of an inch) or millimeters. The angle is usually
expressed in terms of rise/run, or mils/inch. This is due to the very small angles involved.
After all, one degree is equal to 17.45 mils/inch and we are dealing in the 1.0 mils/inch range.
TOLERANCE TYPES
Next, the proper goal needs to be defined for a quality alignment job. As illustrated earlier,
time is not the best parameter to use when a quality alignment job is needed.
Total Indicator Runout (TIR) was probably the first attempt to establish alignment tolerances
and is still used frequently. In fact, many equipment manu-facturers still use TIR in their
installation and maintenance manuals. TIR can be confusing, because the severity is different
from machine to machine. Four mils TIR on one machine can be much worse alignment than
on another. For example, compare Case A and Case B in Figure 4. In case A, the alignment
fixtures are 2 inches apart and in case B the fixtures are 10 inches apart. Four mils TIR could
be an equivalent to 2 mils/inch in case A and 0.4 mils/inch in case B. The same TIR tolerance
results in two different alignment condi-tions. One possibly good, the other most likely bad.

Figure 4 -- TIR Comparison

Another boast commonly heard after a quality (or what is thought to be) alignment job is
complete is, "It was left with moves of three mils, or less." This may very well be the
completion of a quality alignment job. There is also the possibility that it is not. Especially, if
the machine moves are in opposite directions. Consider the following example in Figure 5.
When looking at the machine moves only Case 2 appears as though the alignment is
complete. Machine moves at both pairs of feet are 3 mils. However, at the coupling itself the
offset is 7 mils. Even though the machine moves in Case 1 are double digits at one of the foot
pairs, the offset at the coupling is 1 mil.

Figure 5 -- Machine Moves as Tolerances

The angle is the same where the absolute offset in Case 2 is 6 mils greater than Case 1.
Therefore, the alignment quality of Case 2 is lower.
So it makes sense to express tolerances in the basic types of misalignment, offset and angle.
The offset being measured as close as possible to the power transmission planes. Consistency
is added when tolerances are expressed in offset and angle. Offset and angle are not
dependent upon the size of the machine or the location of the fixtures. Offset and angle
tolerances on one machine have the same severity measurement as any other machine as long
as they have the same operating speed. This does not hold true with TIR or machine moves.
These are very dependent upon the machine dimensions. Therefore, if offset and angle are
used, one tolerance set can be used for the complete plant. True standardization can occur.
Another type of tolerance that can be utilized to give consistency to alignments is jackshaft
tolerances. This is a speciality type of tolerance and should be used when an intermediate
shaft (sometimes called a jackshaft or spool piece) is used between the input and output
shafts or when the horizontal separation between the alignment fixtures is 20" or more.
Therefore, the jackshaft tolerances consist of two angles and , shown in the next figure.

Figure 6 -- Jackshaft Misalignment

This application has power transmission at two distinct locations and is not practical to
measure the offset at each transmission plane. Some theories exist that this type of tolerance
should be used in all cases since there are always two power trans-mission planes. However,

in most close-coupled applications these transmission planes are very close and it is difficult
to place the measurement transducers at these planes. Therefore, it is recommended to use the
standard offset and angle tolerances in these cases.
Tolerance levels should vary with the speed of the machine being aligned. The higher the
speed the tighter the tolerance. The same misalignment at a higher speed causes quicker
fatigue failures because more stress cycles occur in the same period of time.
TOLERANCE SOURCES
There are several sources of alignment toler-ances,...coupling manufactures, component
(motors, gearboxes, pumps, etc.) manufacturers, alignment system manufactures/distributors
and independent consultants. It is recommended that the coupling values are not used. Use
the compo-nent tolerances that are specified in offset and angle or jackshaft format. If these
are in TIR format, they can be converted.
On the next couple of pages are tables and charts of recommended tolerances from alignment
equip-ment manufacturers or those that are 'experienced in the art' of alignment. These should
be used only if component tolerances do not exist. Please keep in mind that these tolerances
are for the hot (operating) condition. One of these could be used as a basis for your alignment
program.
CONCLUSION
The question is...which tolerance set should be used? Some have different evaluation
techniques. CSI uses a combination of offset and angle (or angle and angle for jackshaft
tolerances) to position the alignment condition at an X-Y position with respect to
combination tolerances curves on a graph as shown in Figure 7. Vibralign uses an "Offset
Alignment Zone" which is positioned between the power transmission planes. In order for the
alignment condition to be excellent, the offset has to be under the excellent offset tolerance
through the complete zone.
Back to the question. The answer is, I do not know, they may all work just as well. I am sure
that each source has good arguments why theirs is the best. Upon review, it can be seen that
most of the sets are close, but not entirely the same. In fact, as stated earlier, different
methods of evaluation exist. I suggest that a committee (Oh! No! Not another one of those!)
should be formed to standardize on general alignment tolerances. I mean, standards exist for
dynamic balancing, why not alignment?

Figure 7 -- Alignment Condition on Tolerance Chart

REFERENCES
1. Dodd, V.R., Total Alignment, Chevron Research Company, San Francisco, CA (1974).
2. Evans, G. & Casanova, P., The Optalign Training Book, Ludeca, Miami, FL (1990)
3. Piotrowski, J., Shaft Alignment Handbook, 2nd Edition, Marcel Dekker, New York, N.Y.
(1995).
4. Machinery Alignment Handbook, Vibralign, Richmond, VA (1995)
5. UltraSpec Laser Alignment Training Manual, CSI, Knoxville, TN (1995)

Table 1 -- CSI Recommended Tolerances

Table 2 -- Ludeca Recommended Tolerances

Table 3 -- Vibralign Recommended Tolerances

Figure 8 -- Tolerance Chart from Total Alignment by V.R. Dodd

Figure 9 -- Tolerance Chart from Shaft Alignment Handbook, by J. Piotrowski