6 Steps to Shaft Alignment

Steve Lochard
National Sales Manager
Cascade MVS

In very broad terms, shaft misalignment occurs when the centerlines of rotation of two (2) or
more machinery shafts are not in line with each other during operating conditions. Simply stated,
the objective of shaft alignment is to increase the operating lifespan of rotating machinery.

For machinery installation only the rotating shaft centerlines of different machines are aligned.
Not the feet, not the coupling, not the shaft surfaces, not the machine housing, not the bearings;
only the rotating shaft centerlines. It is important to understand that alignment refers to the
positions of two centerlines of rotation or two rotational axes. Note that the shaft’s rotational
centerline may be different than its machined centerline. Shaft alignment means: Positioning two
or more machines so that their rotational centerlines are collinear at the coupling point under
operating conditions. Collinear means two lines that are positioned as if they were one line.
Collinear as used in alignment means two or more centerlines of rotation with no offset or
angularity between them.

The phrase “coupling point” in the definition of shaft alignment is an acknowledgment that
vibration due to misalignment originates at the point of power transmission, the coupling. It
does not mean that the couplings are being aligned. The shafts are being aligned, and the
coupling center is just the measuring point.

“At operating conditions” is an acknowledgment that machines often move after startup due to
wear, thermal growth, dynamic load shifts, or support structure shifts. Beside the above
considerations, the term shaft alignment also implies that the bearings and shaft are free from
preloads. In properly installed equipment, there are no forces or strains on the bearings and
shafts, except those the designers intended. If the machine is installed with the frame distorted
because of uneven or imperfect base plates, bent feet, pipe stresses, or whatever, then machine
life will be shortened, often significantly.

If you don’t turn the shaft you don’t find the rotational center. The only way to determine
rotational centerlines is to rotate the equipment. There is no series of measurements that do not
involve turning the shafts between readings that can be used to find the rotational centerline.

Any system that takes so-called alignment measurements without turning BOTH shafts is
aligning surfaces, not centerlines of rotation. The results of any alignment efforts where one or
both shafts are not turned are highly dependent upon surface quality, rotor eccentricity, shaft
straightness, and other surface defects. In short: “If you do not turn the shafts, you are not doing
shaft alignment”.

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Notation: When aligning two machines, one machine must be picked to be stationary (STAT).
The other machine is then called the Machine TO BE Moved (MTBM). The two machines are
then referred to as STAT & MTBM. Other common names for the two machines are unmovable
& movable, stationary & movable, target & sight, fixed & moveable, etc. All of these terms are
ways of expressing the convention that one machine is considered fixed, the other to be moved.
The choice of which machine is which is up to the aligner. In many cases it is easiest to pick the
driven to be STAT and the driver to be MTBM.

In the same manner, the machine selected as stationary is usually assumed to be level, square,
and in a desirable state of installation. Even if the assumption is somewhat false, the alignment
can still be done within tolerances. Remember, it is the shaft centerlines that must be aligned to
each other. If the shafts are slightly out of level compared to the base, it does not matter. What
matters is that centerlines of the two shafts form a single line.

Misalignment is one of the most common faults found in rotating equipment. Understanding how
to properly diagnosis and correct for misalignment in plant equipment and how to deal with
common pitfalls while out in the field is essential in doing the job right the first time. The
alignment of shaft centerlines on coupled machines is one of the most important aspects of
machine installation. Contrary to popular opinion, flexible couplings will not always compensate
for even moderate amounts of shaft misalignment. Misalignment is any condition in which the
shaft centerlines are not in a straight line during operation. Misalignment generates unnecessary
forces. Precision alignment removes these forces resulting in reduced vibration and noise levels,
minimized shaft bending and cyclic fatigue, reduced energy costs, and increased bearing, seal,
and coupling life. Shaft centerline misalignment can be classified as either angular or offset (also
called parallel). Angular misalignment occurs when the shaft centerlines meet at an angle. Offset
misalignment occurs when the shafts are parallel, but offset from each other. The misalignment
may be vertical, horizontal, or a combination of the two. Most shaft misalignment is a
combination of both angular and offset misalignment. Another type of misalignment not
associated with couplings is bearing misalignment. The centerlines of two coupled shafts can be
properly aligned, but the bearings on one side of the coupling may be misaligned. Bearings can
be misaligned if they are not mounted in the same plane; if they are not normal to the shaft, i.e.
they are cocked relative to the shaft; or because of machine distortion due to soft foot, an uneven
base, or thermal growth.

Alignment tolerances have often been treated with a halfhearted “just get it close” attitude. But,
alignment tolerances are actually the measurement of a job well done and they provide the
definition of what close actually is. There are two reasons to use a tolerance. The key reason is to
establish goals. If you do not have a goal, how do you know when the job is finished? If there is
not a goal, there cannot be a quality alignment. The second purpose of alignment tolerances is to
establish accountability. Accountability is the evaluation of alignment quality. If there is no
tolerance to compare an alignment to, how can the quality of the alignment be judged?
Accountability can create competition, driving a mechanic to get the job done better.
Misalignment is one of the most common faults found in rotating equipment. Because of the

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frequency of occurrence, machines are often aligned without taking the time to properly diagnose
the machine fault. Diagnosing misalignment in a machine can be difficult because the vibration,
phase, and temperature characteristics are dependent on the type of coupling used. Misalignment
leads to reduced bearing, seal and coupling life. Precision alignment reduces plant operating
costs through reduced maintenance and energy costs as well as reduced equipment downtime.
Equipment optimization is possible with a balance of technology, expertise, and work processes.

There are a number of cost benefits of precision alignment. It can help reduce plant operating
costs by reducing energy costs. Precision alignment also results in increased maintenance
savings through reduced parts consumption and reduced overtime. Finally, it can help decrease
equipment downtime and increase product quality. A recent study found that even small amounts
of misalignment could significantly reduce bearing life. The study found that if, on average, a
motor was offset misaligned by 10% of the coupling manufacturer’s allowable offset, there was a
corresponding 10% reduction in inboard bearing life. Furthermore, if a motor was offset
misaligned by 70% of the coupling manufacturer’s allowable offset, there was a corresponding
50% reduction in inboard bearing life.

The objective of this presentation is to identify a simple shaft alignment procedure that can be
followed for every alignment. Shaft alignment should be an organized and simple process. It is
important to establish a set procedure to perform alignments. This procedure should be followed
for every alignment from beginning to end. After you perform alignments over a period of time
using the same procedure, you will find yourself spending less time per alignment and doing a
much better job.

The following six steps form a comprehensive outline to follow for every shaft alignment.

1. Safety

Review the lock out tag out procedures in affect at your facility. Don’t forget to consider all
potential energy sources in your planning. Disabling the machine at the breaker is NOT
acceptable. Identify any obstacles on and around the machinery that may cause harm if not
removed or contained. Be extra careful when changing shims; thin shims can be very sharp and
you can easily be cut. Don’t take any chances, worn and/or damaged tools should be replaced.

2. Clean-up & Pre-alignment Considerations

First, before you even head out to do the alignment, make sure you have all of your tools. Make
sure your alignment tools are in good condition. Are all the parts in your alignment kit? Do you
have an assortment of shims in your kit or did the last guy use them and not replace them? (That

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never happens!) Do you have the tools you will need to move the machine you will be working
on? You should include a tape measure, feeler and taper gauges, slide calipers, a micrometer and
a wire brush in your alignment kit.

Get a copy of the machine history. Review any issues that may be a problem during alignment.
Has it been aligned before? How long ago? What problems were noted at the time? Were there
indicators of other problems that need to be re-checked? Make a checklist and use it before
leaving the shop. It will save a trip all the way back across the plant!

Next, do a visual inspection of the machine. Check the base plate and/or foundation. Make sure
the base plates are secure and the foundation is still stable and the grout is in good condition.
Clean the foundation of all debris. We are working in thousandths of an inch, so it won’t take
much to alter your alignment. A precision alignment cannot be made on a crumbling foundation.

Look for oil leaks or metal shavings that could indicate larger problems. For motors that have
been in operation for a long period of time, perform a lift check. Excess amount of shaft lift in a
machine with a rolling element bearing may indicate that the inner race of the bearing is loose on
the shaft, the outer race is loose in its housing or there is too much clearance between the balls
and the inner and outer races.

This would be a good time to use your dial indicators to check for excessive shaft and coupling
run out. Run out is the condition in which a rotating object is not concentric with its rotating
center line, also known as eccentric.

Look for damaged or worn components. Check the coupling for looseness and wear and examine
the machine casings and shafts. Look for cracked feet on the machines you are aligning.

Check for any other outward forces, like pipe, conduit or ductwork strain, on the stationary and
movable equipment that will affect your ability to perform a good alignment.

If you plan to use pre-existing shims, make sure they are free of rust and debris. All of that rust
and debris have become part of the shim pack. When working in thousandths of an inch it
doesn’t take a lot of dirt and debris to alter the thickness. We want metal-to-metal contact
between the machine feet, all shims and the base.

Make sure there are not more than 3-4 shims under any foot. This can create a spring effect or
“squishy foot” and induce a soft foot condition. If there are more than an acceptable number of
shims under a foot, use your micrometer to measure the thickness of the shim pack and replace

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them with an acceptable number.
3. Rough Soft Foot Correction

Now, before bolting in the machine, perform a rough soft foot check. The goal in this task is to
correct any obvious rocking of the machine. Use your feeler gage or pre-cut shims to map the
gap between the feet and base. Fill all obvious gaps at the feet. Use your feeler gauge to check
for bent feet and/or sloped bases. Look for any burrs and debris on the feet of the machine.
Finally, perform the bolt tightening sequence. You will find that specifying, recording, and
maintaining a tightening sequence will result in better and quicker alignment. The fact is that
machines will move (both vertically and horizontally) as we tighten down the bolts. This is true
even after we correct soft foot. If you follow a known sequence, you will minimize and make
this movement predictable during the alignment process. Often when making vertical
corrections, aligners will only loosen two bolts at a time to try to hold horizontal position. This
practice is acceptable, but some horizontal movement will likely occur anyway. Therefore, you
should re-loosen all bolts and retighten in the recorded sequence after all vertical adjustments are
complete.

4. Rough Alignment

Rough alignment is performed to expedite the precision alignment process. It is intended to

quickly get the machines “in the ball park”. On close coupled machines (those with no spacer
coupling), rough alignment can be performed with a scale or any straight edge to remove vertical
and horizontal offset misalignment. If using a laser alignment system, it is suggested that angular
misalignment needs not be considered in the rough alignment procedure for close coupled
machines. Laser systems and dial indicators can also be used for rough alignment. Usually, these
tools include instructions for rough alignment. A good rough alignment is important for new
installs because it will help determine where to position the mounting holes and help prevent a
bolt-bound situation during precision alignment.

5. Final Soft Foot Correction

By now you should be ready to perform a precision soft foot check. Soft foot is the condition
where one or two feet of a machine are shorter than the others, much like a table with a short leg.
Soft foot will cause the machine to rock and the measurement values will change continually.
Without proper soft foot correction, precision alignment is virtually impossible.

Soft foot can be caused by too many shims (squishy foot), uneven surfaces, a bent foot (angular
foot) or sloped base or it can be induced by outside forces like pipe strain. If left uncorrected, not
only will you not be able to perform a precision alignment, you will also leave unchecked forces
that can cause shaft deflection.

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Soft foot can be identified with a laser alignment tool, a dial indicator or your feeler gauge. Start
with all four feet tightly bolted down. Release and tighten each foot, one at a time. Use your tool
to record the amount the foot rises when loosened. Record this value for each foot. The foot with
the greatest gap is your soft foot. The values can also be measured at each foot simply using a
feeler gauge.

Once you have determined the soft foot, loosen the bolt at the foot while the others remain
tightened. Use your feeler gauge to measure the gap, front to back, side to side. Measure the gap
to see if it is different in different places under the foot. Use the feeler gauge in this way to detect
a bent foot and determine the correct shim strategy.

Once you have determined whether or not you have a soft foot condition, use shims to correct it.
Keep in mind the number of shims already under the foot. Use your micrometer to measure the
entire shim pack and then determine the best way to correct using 2-3 shims.

6. Final Alignment

Now you are ready to move on to a precision alignment using dial indicators or laser alignment
tools. It seems like a lot of work to get to this point, but it is worth it in the long run. Your
alignment from this point should go much smoother.

Take a set of alignment measurements. Shim and Move machine until you are within allowable
tolerance. Re-measure and verify the success of your alignment.

These six steps should be followed for every shaft alignment. Put this procedure into practice and
you will do a better job, it will take you less time to perform an alignment, and you will be
performing alignments less often.

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6 Steps to Shaft Alignment

Steve Lochard
Cascade MVS
 Steve Lochard
National Sales Manager
Cascade MVS
1705 Gill Road
Dickinson, TX 77539
 6 Steps to Shaft Alignment

• What is Shaft Alignment?

– Rotational Centerlines
– Collinear
– Coupling Point
– At Operating Conditions
 6 Steps to Shaft Alignment

• Precision Alignment

– STAT & MTBM

– Offset Misalignment
• Vertical and Horizontal
– Angular Misalignment
• Vertical and Horizontal
– Results
– Cost Benefits
 6 Steps to Shaft Alignment

• Alignment Tolerances

– “Just Get It Close”!

– Establish Goal
– Accountability
 6 Steps to Shaft Alignment

• Step 1 – Safety

– Lock Out Tag Out

– Working with Shims
– Worn or Defective Tools
 6 Steps to Shaft Alignment

• Step 2 – Clean-up & Pre-alignment

Considerations

– Proper Tools
– Machine History
– Visual Inspection & Clean-up
– Perform Lift Check
– Check Run Out
– Damaged or Worn Components
– Using Shims
 6 Steps to Shaft Alignment

• Step 3 – Rough Soft Foot Correction

– Define Rough Soft Foot

– Map the Gap
– Look for Burrs and Debris
– Perform Tightening Sequence
– Benefit to Rough Soft Foot
 6 Steps to Shaft Alignment

• Step 4 – Rough Alignment

– Define Rough Alignment

– In the Ball Park
– Offset Misalignment
– Angular Misalignment
– Benefit to Rough Alignment
 6 Steps to Shaft Alignment

• Step 5 – Final Soft Foot Correction

– Define Final Soft Foot

– Importance of Final Soft Foot
– Causes of Soft Foot
– How to Identify
– How to Correct
 6 Steps to Shaft Alignment

• Step 6 – Final Alignment

– Define Final Alignment

– Alignment Measurements
– Shim & Move Machine
– Re-measure and Verify Results
6 Steps to Shaft Alignment

Question & Answer

Thank You!