Shaft Alignment
Senior Mechanical Engineer/ Rotating &Static Equipment and piping Specialist /Construction/ Pre-commissioning / Commissioning / Maintenance
Shaft alignment is the process of ensuring that two or more rotating shafts in a machine are properly aligned to minimize stress, vibration, and wear. Misalignment can lead to premature equipment failure, increased energy consumption, and safety risks. Types of Shaft Misalignment 1. Parallel (Offset) Misalignment: The centerlines of the shafts are parallel but not collinear. Can occur in both horizontal and vertical planes. 2. Angular Misalignment: The shafts' centerlines intersect but are not parallel. Can also occur in horizontal or vertical planes. 3. Combined Misalignment: A mix of parallel and angular misalignment. --- Methods for Shaft Alignment 1. Manual Methods: Straightedge and Feeler Gauge: Used for rough alignment by checking gaps and straightness. Dial Indicators: Measures misalignment with precision. Commonly used but requires expertise. 2. Laser Shaft Alignment: Uses laser and sensor systems to measure and adjust alignment. Advantages: Highly accurate, faster, user-friendly, and provides real-time feedback. 3. Optical Methods: Involves precision tools like theodolites to align shafts in large systems. --- Steps in Shaft Alignment 1. Preliminary Checks: Inspect foundations, mounts, and couplings. Ensure there’s no looseness in components. 2. Rough Alignment: Use straightedge or approximate tools for initial setup. 3. Precision Alignment: Use dial indicators or laser alignment tools to measure misalignment. Adjust machinery (e.g., shimming or moving equipment) until tolerances are met. 4. Recheck: Tighten bolts and remeasure to ensure alignment holds under operational conditions. --- Tools for Shaft Alignment Dial Indicator Sets: For manual alignment with precision. Laser Alignment Tools: Brands like SKF, Prüftechnik, and Fluke offer advanced systems. Shims and Adjusters: For correcting alignment. Measuring Software: Digital tools to record and analyze alignment data. --- Importance of Proper Shaft Alignment Reduces wear and tear: Minimizes stress on bearings, seals, and couplings. Saves energy: Reduces friction and power loss. Improves reliability: Reduces maintenance frequency and equipment failure. Ensures safety: Prevents hazardous breakdowns