Quality Tool Box Talk

Mechanical – Preliminary Shaft Alignment

Discipline : Mechanical Doc No : QC-TBT-MEC-006
Activity : Shaft Alignment – Rotating Equipment Sub Activity : Preliminary Shaft Alignment
Date : 05/11/2014

Preliminary shaft alignment is carried out before the machine is released for base plate grouting in order to
ensure the centerlines of the driver and driven units are in the required collinear position. The collinear
position of the shaft centerlines should be achieved both in the vertical and the horizontal planes.

“X” and “Y” in the illustration above should be within the specified tolerances. This is achieved by carrying out
shaft alignment and the topics for discussion are:
A) Types of Misalignment
B) Methods of Shaft Alignment (Reverse Rim, Rim & Face & Laser Alignment)
C) Alignment Fixtures
D) Bracket Sag
E) Shim Requirements
F) Alignment Tolerances
- Axial Spacing Tolerance
- Bolts & Bolt Clearance
- Tolerances Table (Table 1)
G) Grout Forms
H) Dial Indicator Gauge (illustrations)
Note: Laser Alignment to be discussed separately

Shell Iraq Petroleum Development BV Page 1 of 9 QC-TBT-MEC-006

 Quality Tool Box Talk

A) TYPES OF MISALIGNMENT

a) Angular Misalignment
It is the angle between the shaft centerline of two adjacent shafts in both or either of the vertical
and horizontal planes and is normally reported in slope of millimeters of change per decimeter.

b) Parallel Off-set Misalignment

It is the distance between two adjacent and parallel shaft centerlines. This off-set is normally
described in millimeters at the flex element location.

c) Combination Misalignment
A combination misalignment exists when the centerlines of the two adjacent shafts are neither
parallel nor intersect. This misalignment is normally described in both angular and offset terms
(see “a” & “b” above).

Shell Iraq Petroleum Development BV Page 2 of 9 QC-TBT-MEC-006

 Quality Tool Box Talk

B) METHODS OF SHAFT ALIGNMENT

Reverse Rim Method

1) Two calibrated precision dial indicators are mounted on the driver and the driven shaft each.
2) Customized clamps are used to securely hold the dial indicators in place.
3) Both shafts shall be rotated simultaneously in the direction of rotation.
4) Rotate shafts by hand. Use a strap wrench if necessary but never employ a pipe wrench even with
protection in place.
5) Readings shall be at 90° increments in the horizontal and vertical plane.
6) For readings to be considered valid, the readings and zero shall repeat within 0.02 mm. The algebraic sum
of the horizontal readings shall also be equal to the algebraic sum of the vertical readings within 0.05
mm.

Advantages Disadvantages
When both shafts are turned together, the Both machines must be turned to align them
errors of coupling hub run-out are eliminated unless special brackets are made
Axial float errors are eliminated by eliminating Indicator sag must be measured and included in
the face readings the calculation
By spanning a coupling spacer, angular Brackets must be made to fit the shaft correctly
misalignment readings are more sensitive and still swing the shafts through 360°
The method lends itself to both the graphical It is not as accurate for equipment where
and calculated methods of alignment correction coupling diameter is greater than DBSE
Any hub surface disconformity in the
Familiarity of personnel with this method of mechanically indicated surfaces must be
alignment compensated for when rotating only one shaft
at a time
General purpose shaft adapter kits are easily Cost effectiveness of procuring/manufacturing
available reverse dial indicator brackets

Shell Iraq Petroleum Development BV Page 3 of 9 QC-TBT-MEC-006

 Quality Tool Box Talk

Rim & Face Method

1) Rim and Face Alignment is recommended when the coupling hub or shaft end flange diameter is greater than
the spacing between indicators or when one of the train elements cannot be turned.
2) Use Rim and Face alignment only when specified.
3) The dial indicators are mounted on the movable machine.
4) Both shafts shall be turned together unless it is not possible to rotate one of the machinery element shafts
during the alignment process.
5) Rotate shafts by hand. Use a strap wrench if necessary but never employ a pipe wrench even with
protection in place.
6) Instead of two dial indicators for face readings, a single dial indicator for face readings is considered
sufficient for small rotating equipments (where shaft end-play is not foreseen to cause interference).
7) Face readings shall be taken with a dial indicator wherever possible. When there is insufficient space or when
one of the shafts cannot be rotated, micrometer measurements to accuracy of 0.01 millimeter are to be used.
8) The figure below shows the arrangement for three dial rim & face alignment process and the formula to
calculate face displacement.

Shell Iraq Petroleum Development BV Page 4 of 9 QC-TBT-MEC-006

 Quality Tool Box Talk

Advantages Disadvantages
It is more accurate than double reverse dial Unless the three dial rim and face method is
when the machinery train is close coupled and used to substract shaft end-play, it is likely to
the dial indicator span is less than the coupling give erroneous face readings as the shaft is
hub diameter rotated
The rim reading give the off-set and the face
For machinery with spacer couplings, the face
reading(s) give the angularity at the dial
readings do not have as good a resolution as
indicator (easier to understand for mill wright
reverse dial readings.
personnel)
Requires only one shaft to be rotated (but this Rim readings must be corrected for indicator
should be done only when necessary) sag

C) ALIGNMENT FIXTURES

The alignment fixtures/brackets for general purpose machinery may be built by the equipment installer or
the commercially available type (see pictures below) specified by the equipment user may be used. However
and unless otherwise specified, the fixtures/brackets shall be made for each special-purpose equipment train
(API RP 686).

Shell Iraq Petroleum Development BV Page 5 of 9 QC-TBT-MEC-006

 Quality Tool Box Talk

D) BRACKET SAG

To ensure that all indicator readings (from top to bottom of shaft or from bottom to top position) are correctly
taken, the bracket sag present in the fixture must be determined before starting the alignment process. The
following steps must be taken to determine sag of any given bracket set up:
a) Mount the set up on a pipe length and allow the dial indicator to ride on the pipe itself
b) Set the indicator at “0” on top
c) Roll the pipe until the indicator is at the bottom of the pipe
d) The delta reading is algebraically subtracted from the reading obtained at the bottom position

In the example shown below, the bracket sag checked out at 0.05 mm. This reading will always be negative.
Further, it should be remembered that:
Bracket sag need not be considered for the horizontal or side to side readings
Bracket sag shall be checked for each DBSE (Distance Between Shaft End), recorded and taken into
consideration during shaft alignment process

Reading set at 0

Reading: -0.05 mm

Shell Iraq Petroleum Development BV Page 6 of 9 QC-TBT-MEC-006

 Quality Tool Box Talk

E) SHIMS REQUIREMENT (above base plate)

1) Shall be 300 series stainless steel or higher grade

2) A maximum of 5 shims are allowed under any one equipment foot
3) The movable machine shall have a minimum of 3 millimeters of 300 series stainless steel under each
support foot
4) Shims lesser than 0.05 mm in thickness are not permitted
5) Tapered and laminated shims are not permitted
6) The maximum shim stack height shall not exceed 12 mm
7) Only one 3 mm or more shim is allowed on any one mounting foot
8) All shims shall be full bearing. It is not acceptable to cut shims from rolled shim stock
9) Ground shims shall have a surface finish of 64 Ra or a higher finish grade

F) ALIGNMENT TOLERANCES

Axial Spacing Tolerance:

1) For flexible element couplings, the coupling spacer gap length or distance between shaft ends
(DBSE) shall be set as specified in the construction package data package or general arrangement
drawing and held to the applicable tolerance specified in Table 1.
2) For elastomeric couplings, the spacer gap length or DBSE shall be set as required by coupling or
machinery vendor and shall be held to the applicable tolerance mentioned in Table 1.
3) The motor shaft shall be located at magnetic center that is marked out during field or factory run-
in.
4) DBSE shall be corrected for thermal growth as applicable

Bolts & Bolt Clearance

1) Undercutting of hold down bolts for alignment is not permitted.
2) Lock washers are not permitted at machinery hold down bolts.
3) If special washers are not provided by vendor or when standard washers yield at the specified bolt
torque, thick ground plate washers that do not permanently deform shall be installed at the hold
down bolts.
4) Hold down bolts shall not be bolt bound.
5) Unless otherwise specified, after final alignment the hold down bolt holes shall be reasonably
centered upon visual examination.
6) Hold down bolts shall be tightened to specified requirements.

Shell Iraq Petroleum Development BV Page 7 of 9 QC-TBT-MEC-006

 Quality Tool Box Talk

TABLE 1

Activity Tolerances Remarks

Reverse Rim Unless a closer tolerance is
0.05 mm TIR at both indicator locations
alignment specified by manufacturer

Rim & Face alignment 0.05 mm angularity & at centre of coupling -do-

DBSE/DBCE (flexible
+ 0.25 mm when machine’s rotating elements
element & spacer -do-
are in the axial operational position
couplings)

DBSE/DBCE + 0.75 mm when machine’s rotating elements

-do-
(elastomeric coupling) are in the axial operational position

Bracket sag ≤0.08 mm/meter -do-

Legend: TIR - Total Indicated Reading

DBSE - Distance between Shaft Ends
DBCE – Distance between Coupling Ends

IMPORTANT: Refer to the vendor installation manual for specific requirements. If the tolerances required by
equipment manufacturer/vendor are more stringent, alignment shall be carried out to the tolerances specified
therein.

G) GROUT FORMS

All grout forms shall be built of materials of adequate strength and securely anchored and sealed to withstand
the liquid head and forces developed by the grout during placement.
Grout forms shall not be power nailed to the foundation.
The inside surfaces of all grout forms shall have three coats of paste wax applied to prevent grout adherence
(oil or liquid wax is not permitted) and shall be properly sealed to prevent grout leakage.
Grout forms shall have 25 millimeter 45° chamfer strips at all vertical corners and at the horizontal surface of
the grout. All the chamfer edges required in the grout should be incorporated into the forms because epoxy
grout cannot be easily cut or trimmed after hardening.

General Information:
Ground excavations carried out close to a foundation tend to disturb the equilibrium resulting in shaft
misalignment.
Whenever excavation is carried out near a foundation in the intervening period between shaft alignment and
base plate grouting, recheck the alignment and ensure tolerance limits have not been exceeded.

Shell Iraq Petroleum Development BV Page 8 of 9 QC-TBT-MEC-006

 Quality Tool Box Talk

H) TYPICAL DIAL INDICATOR GAUGE (calibrated to 0.01 mm)

Dial gauges are available in different calibrations. Use a gauge that represents a calibration to the decimal
place that is required to be verified.
E.g.: Dial Gauges below are calibrated to 0.01 millimeter.

Shell Iraq Petroleum Development BV Page 9 of 9 QC-TBT-MEC-006