Machinery Alignment – Back to Basics by Sam Pickens

Total Machinery Alignment vs. Shaft-to-Shaft Alignment

In today’s world we all know the importance of machinery alignment but most often we
stop at shaft-to-shaft alignment and consider the job done. When is this not enough: If the
MTBF (meantime between failures) is too high and/or your PdM Division has suggested
additional checks. Naturally we will not attempt to address every situation in existence
but we will take some things into account to consider when shaft-to-shaft alignment only
isn’t adequate or good enough to achieve total alignment to get our desired end results.
Most in-plant maintenance personnel don’t address a full1 alignment every time they
perform an alignment task as certain aspects are addressed during construction and don’t
require coverage during routine maintenance as a rule.

In our new age we have many techniques available from laser (single and dual beam) to
parallels, to feeler gages, to dial indicators and micrometers. Each require a common
ingredient; user knowledge or qualified technicians. And to achieve total alignment we
will have to consider both driver and driven, piping, supports and foundations, plus
consider where the machines are when they are in their hot or running position. And of
course, what is good enough (acceptable tolerance)?

We’ll probably want to know ‘what is good enough’ first so we can establish a set of
tolerances. Are we looking at a general machine train consisting of a 50 HP motor and
water pump? Or, a 2,500 HP motor, driving a propane compressor? Will we need a ‘hot’
alignment exercise or will initial ‘cold’ alignment be adequate? Will this machine have a
spare in a non-critical environment or is the process dependant upon this machine’s
availability? How good is ‘good enough’ or do we want to work within the tech’s
capabilities: if you regularly do one-shot alignment with a five-mil tolerance, why set a
tolerance of 10 mils? That makes sense!

Let’s begin! When we heighten reliability we extend availability or it should work that
way. It will, if we take everything into account.

Our situation: New plant, new installation, new foundation for our 2000 HP four-footed
driver (electric motor), driving two water pumps. We’ll keep this illustration simple or try
not to over-do it so we can easily see complexity in a more simple set of problems. Also,
let’s say we are dealing with sleeve bearings throughout and that the pump is double
suction single volute and we’ll use a gear type coupling in both applications.

Our foundation is one continuous isolated block with sole plates for mounting equipment.
Our piping is properly hung with engineered supports specifically calculated for the
weight of the pipe, insulation and fluid carried and held in place with factory installed
pins2 to be removed after installation and charged with fluid.

Our motor has a huge mass in relation to the stiffness factor of its base whereas the
pump’s relationship is basically rigid. In a situation like this it is best to use optics or laser
leveling devices to shoot-in or bring the base (feed pads) to the same plane prior to
setting the motor as a conventional soft-foot check may not be accurate as the mass may

Sam Pickens 304 373-3676

PO Box 285 Millwood, WV 25262
 Machinery Alignment – Back to Basics by Sam Pickens

overcome the stiffness of the motor’s base thereby letting gravity induce stress be
introduced without detection using conventional means such as the ‘across-the-coupling’
method of either lasers or dial indicators. Even a check at the motor’s foot may be
inaccurate and not give a real picture of the amount of case distortion. We can elect to
measure each foot to ensure they are in the same plane using optics, laser or electronic
levels. This will eliminate the soft foot check later during the alignment process and
guarantee the machine is free of a soft foot.

At this point we know the water temperature average from winter to summer has a mean
temperature of 78oF. Our motor specifications given by the OEM suggest3 we set the
motor five mils (0.005 inches) low due to the thermal rise. Our motor/pump package is a
design package from the pump vendor and requires that the pump’s impellers are set
centered for hydraulic balance with the thrust collar in center of the respective bearing.
With those settings, the motor’s axial setting will be on magnetic center and axial seeking
controlled by a phenolic or aluminum disk within the coupling thus limiting end-float to
+/- 0.025” (+/- 25 mils or 50 mils total float4). Magnetic center has been located and
marked at the factory. Also incorporated in our setup plan is to have a base which will
require the addition of a quarter-inch (¼”) shim plate to bring the pump to elevation so
that future subsidence won’t be an issue peradventure our base were ever to settle.

We’ll start our anchor point with Pump # 1 – see machine sketch below:
(The pump will serve as the fixed or anchor point for setting the motor and Pump 2)

Pump 1 Pmp 2
Motor

Foundation/Base

The motor has no thrust collar thus relying on the pump’s thrust bearing and the phenolic
disk to eliminate hunting or seeking. The disk’s thickness is such to allow the pump’s
shaft to locate hydraulically and allow full freedom for the total axial float of the thrust
bearing.

So, on initial setup we’ll locate Pump #1 to elevation5 and in the center of the anchor bolt
holes and eliminate any soft foot condition if it exists. We’ll do the same for the motor
with the motor sitting on magnetic center. This way we can have the motor centered and
the pump centered in the thrust bearing and measure our air gap between the coupling to
confirm our disk thickness is correct.

On our case problem, Pump #1 will serve as our anchor or fixed machine and we’ll align
the motor and Pump #2 to it, controlling axial position.

Sam Pickens 304 373-3676

PO Box 285 Millwood, WV 25262
 Machinery Alignment – Back to Basics by Sam Pickens

Once we’ve located axial positions of the motor and P-2 we and create a scribe line
and/or setup magnetic bases with dial indicators to monitor position.

Now we have to select the method we want to employ to perform alignment. Accuracy is
our first consideration and speed the second. At this point we’ve already confirmed run-
out tolerances and stack tolerance. Depending on size of machines and bearing clearances
– we can never stack more than 80% of the diametrical clearance of the bearing on some
critical machines if fitted with rigid couplings; a different topic for another time.
Generally, on normal run-of-the-mill machines, no run-out can exceed 2 mils (0.002”)
and stack tolerances should be within three mils per machine. In other words, two mil
run-out on the coupling and 1 mil on the shaft would total 3 mils stack.

Of methods available we have probably two standouts in today’s technology. Most

desirable would be either dual beam laser or indicator reverse. If you have a single beam
system you will want to control axial position and index the machines back to a reference
point each time for every movement.

Our motor will sit five mils low and P-2 will be targeted to be on the same concentric
centerline. At a speed of 1200 RPM we will shoot for a tolerance of +/- 3 mils parallel
and be within an angle of 0o 1’ 0” (this relates to mils by multiplying the tangent of the
angle by the span of the distance swept by the reading device. So, if you had a span of
16” -------- 0.00029 X 16 = ~4.5 mils = tolerance).

Alignment Tolerance Chart

Speed/Category Rigid Semi-Flexible Flexible

Tolerance Mils | HMS Mils | HMS Mils | HMS

0- 300 RPM 2 | 0o 0’ 25” 6 | 0o 1’ 30” 8 | 0o 2’ 0”

301-715 RPM 2 | 0o 0’ 25” 5 | 0o 1’ 15” 7 | 0o 1’ 30”
716-901 RPM 2 | 0o 0’ 25” 4 | 0o 1’ 0” 6 | 0o 1’ 0”
902-1201RPM 2 | 0o 0’ 15” 4 | 0o 0’ 45” 5 | 0o 0’ 50”
1202-1801 RPM 2 | 0o 0’ 15” 3 | 0o 0’ 30” 4 | 0o 0’ 40”
1802-2401 RPM 1 | 0o 0’ 10” 2 | 0o 0’ 20” 3 | 0o 0’ 30”
2402-3601 RPM 1 | 0o 0’ 5” 1 | 0o 0’ 10” 2 | 0o 0’ 25”
3602-7000 RPM 0 | 0o 0’ 3” 0.5 | 0o 0’ 5” 1 | 0o 0’ 15”
7001- nnnnn RPM 0 | 0o 0’ 1” 0.5 | 0o 0’ 3” 1 | 0o 0’ 5”

Mils = Thousandths of an inch; 1 mil = 0.001 inch or 1/1000 inch and 0.001”.
HMS = Hours Minutes Seconds [(degrees, minutes, seconds) 1/60th degree = 1 minute].

NOTE: When engineering or OEM’s engineering has specified a tolerance from plotted or calculated data
(hot data) then that should supercede all other tolerance specification. The chart above will usually meet or
exceed all OEM specifications generally for initial setup. This is especially true when warrantee by the
OEM is mandated to meet their specific number/s.

Sam Pickens 304 373-3676

PO Box 285 Millwood, WV 25262
 Machinery Alignment – Back to Basics by Sam Pickens

We are covering an alignment task of achieving total alignment without the mechanics of
the methodology selected. Here is a set of procedures that work well with all methods.
ALIGNMENT PROCEDURES
 SAFETY; lockout and tag. Rack out fuses and chain valves when necessary
Ensure that the driven machine has no stress from piping if connected or soft foot and that the anchor
bolts are tight
Inspect the feet and base of the machine to be aligned for burrs, roughness, dirt
Evaluate if a temporary spacer is need or useful for this alignment process; note
Inspect coupling and check for run outs – all run outs.
Coupling halves should rotate together if possible for dynamic alignment
Evaluate which method of alignment should be used
Which alignment method is best suited for this job; __________________
Is axial thrusting a factor: ______________
Rough align within 1/16 inch
Collect SAG data and record (calibrate – laser and/or indicators)
Install brackets on machines and record machine dimensions
Check for soft foot; correct as necessary
Record alignment readings
Are they valid? Mathematically correct and repeat?s thrust a consideration?
Calculate shim and lateral shift change
Via computer? Print and file?
Calculator? Record, plot and file?
Make changes and verify & RECORD
If spacer was used, remove at this time
PLOT THE FINAL ALIGNMENT DATA
UNLOCK AND REMOVE TAGS; NOTIFY OPERATIONS
PLACE RECORD AND PLOTS IN MAINTENANCE FILE

After calculations are made – don’t move anything yet! We know how much to add or remove and how
much to the left or right to make our lateral shift. With the hold down or anchor bolts tight, set up magnetic
bases and indicators to monitor lateral shift. Now you can loosen the anchor bolts. Can you loosen two and
leave two tight? If so, make the smallest shim change first; retighten or snug, then loosen the remaining
two, make that change and loosen all anchor bolts. Make your lateral shift and lock down – you’re there.

The next phase is to hook-up the piping. We do not want any induced stresses of any
kind! We will determine the type of gasket required and its compressed thickness and set
our flanges parallel – general consensus is, “maximum tolerance is 10 mils”. However, 5
mils or less is recommended! In addition, you must be able to insert a bolt through each
hole to its mating flange without stress or binding. Then the flanges must be pulled tight
while monitoring with dial indicators. On our machines above we will use this technique
described within. Not all machines require the same technique.

In this instance we will monitor the pump’s flanges ~45o off top center while the bolts are
being tightened. We will shoot for zero deflection but will accept a maximum of two
mils.

Next we will plot all data and machine positions recording everything for future records.

Sam Pickens 304 373-3676

PO Box 285 Millwood, WV 25262
 Machinery Alignment – Back to Basics by Sam Pickens
1
(Full alignment): once foundations and bases are installed, set and correct: they, like
piping stands and hangers are likely to be unaffected by subsidence or normal attrition
factors such as wear and fatigue for many MTBF rebuilds and re-installations.
2
(Pipe hanger pins): upon commissioning a new plant and the piping is charged, it is
necessary to remove the keeper pins in pipe hangers. They may require minor adjusting to
allow the pin to slip freely.
3
(OEM suggest): these are projections based on the norm in a controlled environment.
Your actual operating environment may be different and require a ‘hot’ check using optics
or Acculign methods.
4
(total end-float): this number is derived based on the actual float in the machine’s thrust
bearing. That number, plus 10-15 mils. Typically, a thrust bearing’s float may be from 20-
60 mils depending on size, etc…
5
(Elevation): this is of course important in chemical plants as cooking temperatures need
to be calculated at a given elevation but also an important consideration is ‘level’ at
running speed. If in the event that one end of the machine grows more than the other, then
an offset needs to be considered so that at elevation the machine will also be level as we
may not want rotor weight pushing the rotor against the thrust collar (a consideration
anyway).

About the author:

Sam Pickens has been operating as a consultant for many years through PdM Engineering
and is presently a consultant to various industry. Prior to that he was with ARAMCO in
Saudi Arabia and with Union Carbide and Eastman Kodak making a total of thirty-nine
years of field experience – the end!

Sam Pickens 304 373-3676

PO Box 285 Millwood, WV 25262