ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft...
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Transcript of ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft...
![Page 1: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/1.jpg)
ALIGNMENTALIGNMENT
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1 -Introduction 1 -Introduction
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What is shaft alignment What is shaft alignment
It is collinear of two center lines
Shaft alignment is the proper positioning of the shaft centerlines of the driver and driven components (i.e., pumps, gearboxes, etc.) that make up the machine drive train.Alignment is accomplished either through shimming and/or moving a machine component. Its objective is to obtain a common axis of rotation at operating equilibrium for two coupled shafts or a train of coupled shafts.
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Shafts must be aligned as perfectly as possible to maximize equipment reliability and life, particularly for high-speed equipment.Alignment is important for directly coupled shafts, as well as coupled shafts of machines that are separated by distance spool (those using flexible couplings). It is important because misalignment can introduce a high level of vibration, cause bearings to run hot, and result in the need for frequent repairs. Proper alignment reduces power consumption and noise level, and helps to achieve the design life of bearings, seals, and couplings.
Why it is important to make shaft alignment?
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2- Types OfCouplings
2-Types Of Couplings
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1- Rigid Couplings : It is a metal to metal contact (%100 collinear)
2- Flexible Couplings
*Spacer with shims *Gear
*Grid *Rubber
*Others *Torque converter Alignment
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Motor
Coupling
Equipment
It is collinear of two center lines
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Pump Grouting
Special grouting concrete
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1- RigidCouplings
1- Rigid Couplings
DriverEquipment
2– FlexibleCouplings
2– Flexible Couplings
Driver
*Spacer with shims
Equipment
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*Spacer with shims
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*Spacer with shims
Equipment Driver
Spacer is not connected directly to both hubs ,but through the shims
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*Gear
Equipment Driver
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Equipment
*Grid*Grid
Driver
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Turbine
Stationary Guide wheel
PrimaryShaft
SecondaryShaft
Packing
Torqueconverter
Torqueconverter
Liquid
PumpImpeller
Cooling water
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Pumps Turbine
MOTION
HYDRAULIC ENERGY
HYDRAULIC ENERGY
MOTION
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Normal speed
Guide Blades
Higher speedLower speed
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Guide Vanes
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3 -Alignment
Preparation check list
3 -Alignment
Preparation check list
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Comments N/AOK
Confirm that alignment procedures, dimensional offsets and tolerances are dictated by manufacturer and adhered to the
11
Confirm the foundation grouting& anchor bolts are prepared correctly for specific equipment.
2
3 Confirm soft foot under driver checked & corrected.
Confirm coupling gap checked prior to final alignment4
5
Shaft & Coupling Run outs Complete. (refer to vendor manual for acceptable limits):
Motor shaft run out →
Pump shaft run out →
Pump coupling hub run out →
Pump coupling hub face run out →
Description
Alignment Preparation check list
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Confirm the vendor thermal growth correctly for specific equipment (in case of hot fluid pumping)
6
9 Determine Magnetic centre.
Confirm proper tight for the dial indicator holder and holding rods
10
Determine mechanical centre 8
Confirm the dial indicator is rotated from the top position to the bottom position during the alignment procedure.
11
Confirm the proper dial indicators position during the reversal alignment procedure .
12
Determine the thermal growth if it is not allowable in the vendor document
7
Comments N/AOKDescription
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Alignment Handing over
check list
Alignment Handing over check list
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Confirm that after final code alignment with pipe work is connected, the misalignment tolerance is maintained after releasing spring pipe supports .
Confirm pipe strain checked and corrected.
Ensure guards are fitted and in accordance with area design requirements
Confirm coupling hubs are clean damage free and match marked.
Confirm bearings and seals are clean and free from damage
Confirm suction and discharge nozzles are installed as per design andalignment is correct and stress free.
Confirm free rotation and correct direction is clearly marked.
Confirm driver has been installed and initial alignment completed and accepted.
Date
Sign
Organization
Name and ID No
Completions AcceptanceQuality InspectionInspected/Checked ByCompleted By
13
14
15
16
17
18
19
Comments N/AOKHanding over check list
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1-Types of Alignment1-Types of Alignment
CHAPTER 2
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Parallel misalignmentParallel misalignment
Equipment
Vertical
OR
Horizontal
Driver
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Angular MisalignmentAngular Misalignment
EquipmentDriver
Vertical
OR
Horizontal
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A- Parallel Misalignment
A- Parallel Misalignment
Equipment
Shims
Correcting of Misalignment
I- Vertical Plane
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B- Angular Misalignment
B- Angular Misalignment
Equipment
Shims
I- Vertical Plane
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28
II- HORIZONTAL Plane
A- Parallel Misalignment
A- Parallel Misalignment
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29
31
2 4
II- HORIZONTAL Plane
A- Parallel Misalignment
A- Parallel Misalignment
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30
31
2 4
B- Angular Misalignment
B- Angular Misalignment
II- HORIZONTAL Plane
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31
31
2 4
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32
31
2 4
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2 - Dial indicatorsTypes and
Functions.
2 -Dial indicators Types and
Functions.
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• 1- Balanced-Type
• 1- Balanced-Type
10-10-20
30
40
-50
20
-30
40
50
Negative directionStem moves out
positive directionStem moves in
Dial indicators Types and Functions
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• 2 - Continuous Type
• 2 - Continuous Type
10
30
20
40
50
Small needle
60
7080
90
100
110120
130
140
150
160
170
180190
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1 - Preparationon Alignment
1 -Preparation on Alignment
CHAPTER 3
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Measure and correct Measure and correct
*Magnetic centre
*Mechanical centre
*Thermal growth
*Run out
*Soft foot
*Pipe strain
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EQUIPMENTEQUIPMENTPLANT LINEPLANT LINE
* Pipe strain* Pipe strain
X
PLANT LINEPLANT LINE
Maximum 0.002 in
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* Soft foot* Soft foot
One driver leg is not settled on the base
Maximum 0.002“
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* Run out* Run out
Maximum 0.002“
EQUIPMENT SHAFT
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Driver
* Thermal growth for hot liquid pumps
* Thermal growth for hot liquid pumps
X = Thermal growth
Equipment
1 -Apply the alignment procedure for the pump at ambient Temp.2 -Heat up the pump by opening the start up bypass for ½ hrs .
3 -Put the dial indicator on the coupling rim and adjust to zero reading4 -close the bypass
5 -Take the dial indicator reading after 24 hrs.6 -This reading is the thermal growth
7 -Add the thermal growth reading as a shims under the driver legs
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Equipment
1- Apply the alignment for the compressor at ambient Temp. 2- Go to manufacturer catalogue and read the thermal growth amount. 3- Add the thermal growth reading as a shims under the driver legs
* Thermal growth for Compressors
* Thermal growth for Compressors
X = Thermal growth
Driver
After minutes of Starting
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43
Equipment
This design is to avoid any thermal growth
As thermal expansion will be in all directions
Cooling
water
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Driver
44
• *Magnetic centre.
• *Magnetic centre.
Magnet
Magnetic centre
Run the motor
Electrical motors have no thrust bearingsas they have instead a magnetic center
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SAGSAG
The attachment that will be used
Bar Sag on 12 O'clock Position
Measurement of bar sag.
Piece of Pipe
Steel block
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SAGSAG
SAGSAG
Piece of Pipe
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2- How To DoAlignment
2-How To Do Alignment
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Equipment
48
Driver
Gauge Pointer
does not move around the rim
Motor and Equipment shaft
Rotate in the same time
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EquipmentDriver
EquipmentDriver
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VERTICAL READINGSVERTICAL READINGS
Parallel actualmisalignment
Parallel reading 2xDial indicator
x
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Parallel actualmisalignment
HORIZONTAL READINGSHORIZONTAL READINGS
2x
x
If both shafts rotate or one shaft rotates ,the dial indicator reading is the same ,and is equal to double value of the actual Misalignment amount
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D2
D3
D1
1-Reversal Alignment 1-Reversal Alignment
F
M
Inboard Out board
DriverEquipment
![Page 53: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/53.jpg)
F
M
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PARALELL READINGSPARALELL READINGS
54
12 Ock
6 Ock
Fixed Movable
0
0
36 0
0
64
12 Ock
6 Ock
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PARALELL READINGSPARALELL READINGS
55
12 Ock
6 Ock
Fixed Movable
0
020
0
0 40
12 Ock
6 Ock
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1- ReversalAlignment
CalculationMethod
1-Reversal AlignmentCalculation
Method
CHAPTER 4
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HORIZONTALLY
D 1INBOARD +FH {= MH - FH } D 2
D 1 = D 2=
D 3= Sag = ( 0 )
OUTBOARD +FV
{= MV - FV } D 3D 1
OUTBOARD +FH {= MH - FH } D 3D 1 Mils
VERTICALLY
INBOARD +FV
{= MV - FV } D 2D 1
MV +32
/2 /2
18FV
MH
/2
+20
/2
FH10
F M0
0
36
20
0
0 40
64
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Inboard
D1
D2
F
FV
58
VERTICALLY
INBOARD +FV {= MV - FV } D 2D 1
M
MV
INBOARD = X + FV
FV
MV- FV
X
D2
D1MV- FVX = }
}
X=
D2
D1MV- FV
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Out board
D1
F
FV
59
VERTICALLY
M
MV FV
MV- FVY
D3
OUTBOARD +FV {= MV - FV } D 3D 1
OUTBOARD = Y + FV
D3
D1MV- FVY = }
}
Y=
D3
D1MV- FV
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D1 = 4 in D2 = 8 in D3 = 16 in
Sag = ( 0 )
HORIZONTALLY
4INBOARD +10 + = 30 {= 20- 10 } 8
OUTBOARD +18 + = 74{= 32 - 18 }
164
VERTICALLY
INBOARD +18 + = 46{= 32- 18 } 84
OUTBOARD {= 20 - 10 } 164 Mils +10 + = 50
MV +32
/2 /2
18FV
MH
/2
+20
/2
FH10
F M0
0
36
20
0
0 40
64
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2- ReversalAlignment Graphical
Method
2-Reversal AlignmentGraphical
Method
![Page 62: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/62.jpg)
VerticallyVertically
Inboard
MMV
D1
D2D3
FFV)+(
Outboard
Remove shims
Add shims
62
![Page 63: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/63.jpg)
EXAMPLEEXAMPLE
Inboard Outboard
F M Add shims
Remove shims18 mils
16 in
32 mils
4 in
8 in
FV = 18 milsMV = 32 mils
![Page 64: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/64.jpg)
Outboard
M
MH
D1
Inboard
D2
D3
F
FH
HorizontallyHorizontally
645/3/2006
![Page 65: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/65.jpg)
EXAMPLEEXAMPLE
16 in
8 in
Inboard
10 mils
4 in
20 mils
F M
Outboard
FH = 10 milsMH = 20mils
![Page 66: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/66.jpg)
D1 D 2 D 3
2 4 9
0 -40
ADD shims
20 0 0 -23 REMOVE shimsMove towards 9
Move towards 3
-30 0-15 -1 -20 1-15 -20
10 -15 -12 -20
Inboard (vertical)
Outboard (vertical)
Inboard (Horiz.)
Outboard (Horiz)
-25-38-33-87
Bar Sag(F)
Bar Sag(M)
0 0
Move towards 3
Move towards 3
ADD shims 0
ADD shims 0
0
0
MF
3-Reversal Alignment Software 3-Reversal Alignment Software
![Page 67: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/67.jpg)
InboardX Out board
Y
P
D/2
A
P = Parallel ReadingA = Angular Reading
Rim and Face AlignmentRim and Face Alignment
Equipment Driver
![Page 68: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/68.jpg)
OROR
Inboard Out boardX
Y
DriverD / 2
Equipment
68
PA
![Page 69: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/69.jpg)
PARALELL READINGPARALELL READING
69
12 Ock
6 Ock
VERTICAL
3 Ock9 Ock.
HORIZONTAL
![Page 70: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/70.jpg)
ANGULAR READINGANGULAR READING
70
0X
12 Ock
6 Ock
VERTICAL
![Page 71: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/71.jpg)
71
ANGULAR READINGANGULAR READING
X
3 Ock
9 Ock
0
HORIZONTAL
![Page 72: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/72.jpg)
1-Rim and Face Alignment Calculation
Method
1-Rim and FaceAlignment Calculation
Method
CHAPTER 5
![Page 73: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/73.jpg)
CALCULATION METHOD
CALCULATION METHOD
A0
0
-16
+8
P
-6
0
0 -14
A = ANGULAR READINGP = PARALLEL READING
![Page 74: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/74.jpg)
VERTICALLY
INBOARD XD AV – PV Mils=
OUTBOARD = D AV –PV Mils Y
AV
D
Y
X
InboardPV Outboard
PV
PV
Inboard –pv X
AV=
D
![Page 75: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/75.jpg)
75
X= Y= D=
Sag = - 1
-16 AV
P0
0 0
0
A
-14
-16
+8
-6
SAG = +1
-2
-3
/2
PV
AH+8-7PH
/2
VERTICALLY
INBOARD XD AV – PV Mils=
HORIZONTALLY
INBOARD XD AH – PH Mils=
OUTBOARD = YD AH – PH Mils
OUTBOARD = D AV –PV Mils Y
![Page 76: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/76.jpg)
X = 4 inY = 12 inD = 4 inSag = -1
76
-16 AV
P0
0 0
0
A
-14
-16
+8
-6
SAG = +1
-2
-3
/2
PV
AH+8-7PH
/2
124OUTBOARD = { -16 } -( –2) - =46
HORIZONTALLY
INBOARD { 44 8 } -( – 7) + =15=
INBOARD { 44 -16 } -( –2) - =14=
VERTICALLY
124OUTBOARD = { 8 } -( –7) + =31 Mils
![Page 77: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/77.jpg)
2 -Rim and FaceAlignment
Graphical Method
2 -Rim and Face Alignment
Graphical Method
![Page 78: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/78.jpg)
VerticallyVertically
D
Y
X
AV)-(
InboardPV
Outboard
PV
PVPV
![Page 79: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/79.jpg)
AV = -16
D = 4
Y = 12
EXAMPLE
PV = - 2
Inboard
Outboard
PV = - 2
X = 4
PV
AV = - 16 mils
PV = - 2 mils
![Page 80: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/80.jpg)
80
HorizontallyHorizontally
AH
D
Y
X
Inboard
PH
Outboard
PH
PH
![Page 81: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/81.jpg)
EXAMPLEEXAMPLE
AH = +8
D = 4
Y = 12
X = 4
Inboard
PH =-7
Outboard
PH = - 7PH = - 7PH = - 7 milsAH = + 8 mils
![Page 82: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/82.jpg)
HorizontallyHorizontally
AH = +8
D = 4
Y = 12
X = 4
INCHES
Outboard
Inboard
+7
If PH = +7If PH = +7
![Page 83: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/83.jpg)
D X Y Sag
2 4 8 0
0 0
Remove Shims
-12 0 0 0 Add shims
Move to 3 O'clockMove to 9 O'clock
44 0
-6 PH 0 AH
-22
-22
6
6Outboard (Horizontal)
Outboard (Vertical)
Inboard (Horizontal) Move to 3 O'clock0
0 Inboard (Vertical)
Move to 3 O'clock
Remove Shims
Remove Shims
0
0
P A
3-Rim and Face Alignment Software 3-Rim and Face Alignment Software
![Page 84: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/84.jpg)
1 - OpticalAlignment
1 -Optical Alignment
CHAPTER 6
![Page 85: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/85.jpg)
Inboard Out board
Driver
M
Equipment
F
Optical AlignmentOptical Alignment
Transducer Reflector
![Page 86: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/86.jpg)
Reflector
Shaft
BracketBracket
ChainSIDE VIEWSIDE VIEW
![Page 87: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/87.jpg)
Chain
VERTICAL POSITIONADJUSTTMENT
Bracket
90 PRISM0 HRIZONTAL
ANGLEADJUSTTMENT
Shaft
![Page 88: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/88.jpg)
SCRATCH-RESISTANCE LENS
SCRATCH-RESISTANCE LENS
POEWRDATA CABLE
POEWRDATA CABLE
GREEN LED:INDICATES BEAM ADJUSTEMENT
GREEN LED:INDICATES BEAM ADJUSTEMENT
RED LED:LASER ONWARNING
RED LED:LASER ONWARNING
LOCKING KNOB
LOCKING KNOB
HOUSING MARK =CENTER OF
BRACKET POSTS
HOUSING MARK =CENTER OF
BRACKET POSTS
TransducerTransducer
![Page 89: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/89.jpg)
REFLECTORREFLECTOR
Rotate the side thumb Wheel to raise or lower the reflector
Rotate the side thumb Wheel to raise or lower the reflector
This lever to lock The reflector position
This lever to lock The reflector position
1 -PRESS and remove transducer cap.-The laser beam now is on.
-Leave the reflector cap on for now .-Beam strikes the cap, it should be visible.
-Hold a sheet of paper to locate the beam
1 -PRESS and remove transducer cap.-The laser beam now is on.
-Leave the reflector cap on for now .-Beam strikes the cap, it should be visible.
-Hold a sheet of paper to locate the beam
M
![Page 90: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/90.jpg)
HORIZONTALADJUSTMENT
HORIZONTALADJUSTMENT
VERTICAL ADJUSTMENT
VERTICAL ADJUSTMENT
REFLECTORREFLECTOR
![Page 91: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/91.jpg)
OFF Beam misses detectorRed Blinks quicklyGreen Is OFF
END Beam hits non linearized area of detectorRed & Green Blinks quickly
Alternatively
COORDINATES Beam hits area of detectorRed & Green Blinks Slowly Together
OFF
END
-2 1
![Page 92: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/92.jpg)
1 -PREPARING FOR ALIGNMENT PROCEDURE 1 -PREPARING FOR ALIGNMENT PROCEDURE
a- Solid flat foundation
b- Machine mobility ( 2 mm higher & screw type positioning )
c- Soft foot ( Must be checked immediately)
d- Thermal growth
![Page 93: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/93.jpg)
HORIZONTAL MACHINE ALIGNMENTHORIZONTAL MACHINE ALIGNMENT
Select Cycle through with andDIM
1-Transducer to reflector
2-Transducer to coupling center
3-Coupling diameter
4-RPM
5-Transducer to front feet
6 -Front feet to rear feet
![Page 94: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/94.jpg)
1
2
3
4 RPM
5 6
DIM CONFIRM EACH ENTERY WITH
ENT
![Page 95: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/95.jpg)
1-Transducer to reflector
120 mm
2-Transducer to coupling center60 mm
DIM
![Page 96: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/96.jpg)
3 -Coupling diameter D
4-Transducer to front foot, right m/c 180 mm
DIM
![Page 97: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/97.jpg)
BEAM DEFLECTOR
DIM
![Page 98: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/98.jpg)
5-Front foot to back foot , right m/c
DIM
![Page 99: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/99.jpg)
Rotate the side thumb Wheel to raise or lower the reflector
Rotate the side thumb Wheel to raise or lower the reflector
This lever to lock The reflector position
This lever to lock The reflector position
1 -PRESS and remove transducer cap.-The laser beam now is on.
-Leave the reflector cap on for now .-Beam strikes the cap, it should be visible.
-Hold a sheet of paper to locate the beam
1 -PRESS and remove transducer cap.-The laser beam now is on.
-Leave the reflector cap on for now .-Beam strikes the cap, it should be visible.
-Hold a sheet of paper to locate the beam
M
5-Laser beam adjustingM
![Page 100: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/100.jpg)
• Case Studies For Alignment Failure
CHAPTER 7
![Page 101: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/101.jpg)
A- Bearings Failure
![Page 102: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/102.jpg)
THRUST BEARINGTHRUST BEARING
ball Bearingsball Bearings
roller Bearingsroller Bearings
Tilting pad BearingsTilting pad Bearings
RADIAL BEARINGRADIAL BEARING
![Page 103: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/103.jpg)
NON-DRIVE END DRIVE END
HANGED BEAMIMPELLER
HANGED BEAMIMPELLER
Thrust Ball Bearings
![Page 104: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/104.jpg)
Thrust Ball Bearings
Thrust Ball Bearings
![Page 105: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/105.jpg)
MECHANICAL SEAL
BEARING HOUSING
![Page 106: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/106.jpg)
Thrust Load
Radial Load Radial LoadRadial Load
![Page 107: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/107.jpg)
DRIVE END
NON-DRIVE END
IN-BETWEEN TWOBEARINGS IMPELLER
IN-BETWEEN TWOBEARINGS IMPELLER
Thrust Pad Bearings
![Page 108: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/108.jpg)
Mechanical seal and bearings arrangementMechanical seal and bearings arrangement
Equipment
![Page 109: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/109.jpg)
THRUST PAD BEARING
THRUST COLLAR THRUST SHOESTHRUST SHOES
![Page 110: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/110.jpg)
SHAFT
THRUSTCOLLARTHRUSTCOLLAR
BASE RING
LEVEL PLATES
THRUST SHOES
CASING
![Page 111: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/111.jpg)
![Page 112: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/112.jpg)
![Page 113: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/113.jpg)
Titan 130 Thrust Bearing
![Page 114: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/114.jpg)
![Page 115: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/115.jpg)
![Page 116: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/116.jpg)
Radial Tilt-Pad Bearing
![Page 117: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/117.jpg)
RADIAL TILTING PAD BEARING
RADIAL TILTING PAD BEARING
SHAFT
CASING
Radial Load
![Page 118: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/118.jpg)
Oil WedgeOil Wedge
Shaft
Friction EffectOil Wedge Effect
![Page 119: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/119.jpg)
Oil WedgeOil Wedge
Oil adhere to the rotating shaft
Oil squeeze between shaft and bearing pad forming a solid
oil wedge
![Page 120: ALIGNMENT 1- Introduction What is shaft alignment It is collinear of two center lines Shaft alignment is the proper positioning of the shaft centerlines.](https://reader035.fdocuments.us/reader035/viewer/2022081419/56649d895503460f94a6e6e1/html5/thumbnails/120.jpg)
RADIAL TILTING PAD BEARING
RADIAL TILTING PAD BEARING
PIN
CASING
OIL
TILTING PAD
SHAFT
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B- Pumps Cavitations Failure
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IN PUMPS
NPSHA < NPSHR NPSHA < NPSHR
WHENWHEN
CAVITATION OCCURS
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CAVITATION CAN OCCURin
CAVITATION CAN OCCURin
CENTRIFUGALPUMPS
POSITIVE DISPLACEMENTPUMPS
ANDAND
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It is an action of fluid vapor attack on the parts of equipment which produce suction pressure less than vapor pressure of the pumped fluid.
What is cavitations phenomenon
What is cavitations phenomenon
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This action will cause: loss of the weakestcomponent element of suction parts materialdue to bubble explosion on the surface of suction parts causing cavities .
Vapor bubble explosion on
the parts surface could be
10,000 psi.
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FLUID VAPORBUBBLES
Pump suction parts
Pump suction parts After attack
cavities
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CARBON STEEL
CAST IRON STIANLESS STEEL
BRONZ
BRASS
THE WEAKEST ELEMENT( LOST ELEMENT )
SUCTION PARTS MATERIAL
CARBONCARBON
ZINCZINC
LOST ELEMENTSIN SUCTION PARTS
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Cavitations effect on an impeller, indicated by the cavities appearance of cavitated regions on the surface
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Damage to the pressure side of the vane from discharge recirculation
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What is Cavitations Effect
What is Cavitations EffectImpeller deteriorationImpeller deterioration
Decrease discharge pressureDecrease discharge pressureDecrease pump flow rate Decrease pump flow rate
Increase vibration level Increase vibration level
Bearings & M/S failureBearings & M/S failure
1- CENTRIFUGAL PUMPS1- CENTRIFUGAL PUMPS
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Suction valve deteriorationsSuction valve deteriorations
2- RECIPROCATING PUMPS2- RECIPROCATING PUMPS
Spring RuptureSpring RuptureDecrease discharge pressureDecrease discharge pressure
Decrease pump flow rate Decrease pump flow rate
Piston Damage Piston Damage
Cylinder Head Damage Cylinder Head Damage
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YOU CAN GET FROM PUMP MANUAL
1- NET POSITIVE SUCTION HEAD REQUIRED
NPSH NPSH
2- NET POSITIVE SUCTION HEAD AVAILABLE
YOU CAN CALCULATE FROM PUMP SITE
TO AVOID SUCTION CAVITATION AND FOR SAFE OPERATION
NPSHA > NPSHR NPSHA > NPSHR
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What is the parameters affecting NPSHAWhat is the parameters affecting NPSHA
SUCTION PIPE LENGTH
LIQUID SPECIFIC GRAVITY
LIQUID VISCOCITY
INTERNAL SURFACE OF SUCTION PIPELIQUID SURFACE ALTITUDE
VAPOR CONTAMINATIONSUCTION PIPE LEAKSSUCTION PRESSURELIQUID TEMPERATURE
SUCTION PIPE DIAMETER
LIQUID VAPOR PRESURE
ATMOSPHERIC PRESSURE
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HOW TO IMPROVE
NPSHAHOW TO IMPROVE
NPSHA
SHORTEN THE SUCTION PIPE LENGTH
INCREASE SUCTION PIPE SIZE
DECREASE SUCTION LIQUID TEMP.
DECREASE SUCTION NEGATIVE ALTITUDE
INCREASE SUCTION POSITIVE ALTITUDE
STOP THE PIPING SUCTION LEAKS
RENEW THE SUCTION PIPE
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liquid specific gravity Sp.gr
Z liquid surface height ft
PS Pump suction pressure psig V liquid velocity ft/sec
Pf Friction Pressure drop psi Pa Atm. Pressure psi Vp Vapor pressure psia
g 32.2 ft/sec.sec h L Suction head loss ft
Vessel pressure psig PSV
PVS
ZPS v
NET POSITIVE (+) SUCTION HEADNET POSITIVE (+) SUCTION HEAD
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2V
2g
ft2
sec=ft
2sec
=ft
2sec 2
ft2sec
= ( ft )
P
Sp.g
Lb
Lb=
2
ft 3
=ft ft 3
2ft= ( ft )
EQUATION & DIMENTIONS
Z +V
2g
2
NPSHA = ( ft )
{ P sva – Vp } 2.31
+
Sp.gr
- hL
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NPSHA NPSHA IS
IS
NOT NOT
OR OR
PS
THE SUCTION GAUGE PRESSURE
PVS
Z
LIQUID LEVEL IN THE SUCTION VESSEL
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V
11
Z + V2g
2 { (P vs +Pa) – Vp } 2.31 +
Sp.gr- hLNPSHA =
General Equation
PVS
Z
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IF The Suction pressure is known
- hL= Z+Ps
Sp.gr
P sva
Sp.gr
Z + V2g
2 { – Vp } 2.31 +
Sp.gr- hL
P sva PsaNPSHA =
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NPSHA =
PS
v
22
V
2g
2{ Psa – Vp } 2.31
+Sp.gr
( ft )
If The Suction pressure is known
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Z < hL
PS
PositiveReading
Boiled water
CAVITATIO
N OCCURED
Z
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PS
PVS
PS
ATMS
Negative Pressure
NO
CAVITATIO
N
Z < 6m
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PracticallyPracticallyPS
- Z = 6 mt of water- Z = 6 mt of water
ATMS
SUCTION NEGATIVE ALTIDUDE NOT MORE THAN
6 METERS
FOR ANY TYPE OF PUMPS
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76 Cm MERCURY
ATMOSPHERIC PRESSURE
SPACE
10,033 mt OF WATER
water
SPACE
ATMS ATMS
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10,033 mt OF WATER v
PS
v
VACUUM
PS
PS
ATMS
Pump Eff.= 100%
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CENTRIFUGAL PUMPS LOSSES
CENTRIFUGAL PUMPS LOSSES
Q g.p.m.
100 200 300 400 500
H ft
10
20
3
0
40
5
0
6
0
ACTUAL CURVE
FRICTION LOSSEDDY LOSS
LEAK LOSS HEAT LOSSTHEORITICAL
CURVE
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6 mt WATER v
PSv
PS
PS
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1
T P
FIG-2
VAPOR PRESSUREVAPOR PRESSURE
FIG-1
1PT
1- Heat up a little of water in a pot up to boiling point 100 C ( valve 1 is opened)
2- Take off the heating source, simultaneously close valve 1.
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Closed
T P Gauge
3- During cooling down, Start to record the P Gauge relevant to Temp.
4- Apply Absolute pressure Equation .
P Absolute P Gauge + 1 (bar)
Cool Down
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5- Record the Absolute Liquid vapor pressure.
100
0
1
15
- 0.98
0.02
80
- 0.5
0.5
- 0.7
70
0.3
- 0.3
0.7
9095
- 0.1
0.9 Vapor Pressure
P Gauge
Temp C
P Gauge + 1 ( bar ) absolute
Vapor Pressure
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The absolute pressure exerted by the equilibrium vapor of a liquid when confined in a closed Previously evacuated tank
GPSA 1-7
T = CONSTANT
Liquid vapor
Liquid
Vapor Pressure
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Solution
Compare with NPSHR
Examples
Crude oil level is 8 feet above center line of a pump , Vessel pressure is AtmosphericVp is 4 psia Sp gr. is 0.8 Friction loss : 12 ft of liquid Atmospheric pressure is 14.7 psia
( Neglect velocity head (
NPSHA Z +{ (Psv + Pa) – Vp } 2.31 Sp.gr
- hL=
8 +{ 14.7 – 4 } 2.31 0.8
- 12=
= 8 + 31 - 12
= + 27 ( ft )
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ExamplesCrude oil level is 8 feet above center line of a pump , Vessel pressure is AtmosphericVp is 14 psia Sp gr. is 0.85 Friction loss : 2 ft of liquid Atmospheric pressure is 14.7 psia
Solution
Compare with NPSHR
NPSHA Z +{ (Psv+ Pa) – Vp } 2.31
+Sp.gr
- hL=
8 +{ 14.7 – 14 } 2.31 0.85
- 2=
= 8 + 2 - 2 = + 8 ( ft )
( Neglect velocity head (
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SolutionSolution
= + 12.8 ( ft )
Compare with NPSHR
ExamplesExamples
If the liquid level Z = - 12 ft , Friction loss is 1 ft of liquid
, Atmospheric pressure is 14.7 Psia. at 150 F , water sp gr. is 0 982 .
,Vp = 3.7 psia
NPSHA
( Pa – Vp ) 2.31 hL
Sp gr.Z ( ft ) = +
( 14.7 – 3.7) 2.31 1 0.982
-12 ( ft )
= +
( Neglect velocity head (
FIND NPSHA
negative
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ExamplesIf crude pump suction pressure is – 5 psig Vp. is 4 psiaSp gr. is 0.8 , Atmospheric pressure is 14.7 psia.
Solution
Compare with NPSHR
FIND NPSHA
( Neglect velocity head (
= + 16 . 46 ( ft )
+ ( ft )={ ( 14.7 - 5 ) – 4 } 2.31 0.8
NPSHA ( ft )=Sp.gr
{ (Ps + Pa) – Vp } 2.31
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ExamplesIf crude pump suction pressure is – 5 psig Vp. is 12 psiaSp gr. is 0.8, Atmospheric pressure is 14.7 psia.
Solution
Compare with NPSHR
FIND NPSHA
negative
= ( - 6.6 ) ( ft )
NPSHA ( ft )=Sp.gr
{ (Ps + Pa) – Vp } 2.31
( ft )={ ( 14.7 - 5 ) – 12 } 2.31 0.8
( Neglect velocity head (
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ExamplesExamplesIf the liquid is butane and level is z = - 8 ft System pressure is 60 psia. Temperature is 90 F Vp = 44 psia at 90 F, butane sp.gr is 0.58
Friction loss : 12 ft of liquid,
Compare with NPSHR
Solution
= + 43.7 ft
NPSHA
( Psva – Vp ) 2.31 hL
Sp gr.Z ( ft ) = +
( 60 – 44 ) 2.31 hL
0.58.- 8 ( ft )
= +
( Neglect velocity head (
FIND NPSHA
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Examples
If crude pump suction pressure is +1 psig Vp. is 13 psiaSp gr. is 0.85, Atmospheric pressure is 14.7 psia.
= + 7.33 ( ft )
Compare with NPSHR
Solution
NPSHA ( ft )= Sp.gr
{ Psa – Vp } 2.31
( ft )= { ( 14.7 + 1 ) – 13 } 2.31 0.85
FIND NPSHA
( Neglect velocity head (