Controlled thermal movement aids coupling alignment

Shaft alignment is a critical component in keeping a coupling aligned. While most couplings can tolerate some misalignment, they operate much more efficiently and with much longer service lives when simple precautions and procedures are in place. One area of potential misalignment – yet one that is fairly simple to address – is that of thermal movement.

By Bob Boyle, Director – Power Transmission Products Applied Industrial Technologies, Cleveland, OH July 1, 2006

Shaft alignment is a critical component in keeping a coupling aligned. While most couplings can tolerate some misalignment, they operate much more efficiently and with much longer service lives when simple precautions and procedures are in place. One area of potential misalignment — yet one that is fairly simple to address — is that of thermal movement. Heat buildup from the friction generated by moving parts can cause machinery to expand which, in turn, can adversely affect shaft alignment.

The amount of thermal movement can be predicted by knowing the following factors:

  • The construction material of the machinery

  • Amount of temperature change

  • Distance between shims and shaft centerline

    • Thermal movement can be calculated from:

      G = TLC

      where G = Thermal growth, mils; T = Temperature change, degrees; L = distance between shims and shaft centerline, inches; C = growth factor.

      Common growth factors for various machinery materials are:

    • Aluminum = 0.0126

    • Bronze = 0.0100

    • Cast iron = 0.0059

    • Stainless steel = 0.0074

    • Mild steel = 0.0063

      • Fig 1. Thermal growth for a pump/motor assembly.

        For example, consider the simple pump/motor assembly shown above in Fig. 1. Both components are constructed from mild steel; therefore, growth factor C = 0.0063. For a temperature change T of 40 degrees and centerline distance L of 14 inches, thermal growth is:

        G = 40(14)(0.0063) = 3.53 mils or 0.0035 inches.

        Most machinery must be misaligned cold so that the shafts are collinear at normal operating conditions. Graphing the move above shows that the pump does not move (no change in temperature) and the motor rises an estimated 0.0035 in. (3.53 mils).

        Aligning machinery

        There are many ways to move machinery to align rotating equipment, and all must be controlled and accurate. Any alignment method, regardless of its accuracy in measuring misalignment, is useless if proper precautions are not taken and correct procedures are not followed.

        Alignment specialists continually discuss whether vertical or horizontal moves should be made first. Typically, during the rough adjustment stage, once the machine is adjusted to its proper vertical alignment, slight horizontal adjustments will not change vertical alignment. This helps support the case that vertical alignment be done first.

        Once rough vertical adjustments have been made, a horizontal move sometimes must be made to provide correction for alignment errors introduced during the adjustment stage. Any alignment process may involve some alternating from vertical to horizontal until precision alignment is reached.

        Vertical moves : Dial indicators are not required to determine any change in the vertical direction, but they can be helpful to check for any spring effect or soft foot created when moving the machine. No shim should be installed without first verifying its thickness with a micrometer. Regardless of any information printed, stamped or etched on the shim, use a micrometer to double-check thickness.

        Fig. 2 Foundation with jack screws installed.

        Fig. 3 Moving large machines horizontally without jack screws.

        Fig. 4 Indicator positioning to monitor moves. When making vertical adjustments, never loosen all hold-down bolts at the same time. Rather, loosen only two bolts at a time. Loosening all of the hold-down bolts at one time may change the entire foot configuration if the machine is raised. This is particularly true if any of the feet have been corrected for soft-foot conditions using a tapered or step shim.

        Also, leaving two hold-down bolts in place reduces the chances for an uncontrolled move. Uncontrolled movement of the machine can change its horizontal, axial or vertical positioning, negating any previous adjustments.

        Loosen the bolts on either the left or right side of the machine. Then, raise that side just enough to make the shim change. Raising the machine too high can bend the feet that are still bolted down. Once the machine is raised enough to make the shim change, remove the shims from beneath each foot and add or subtract the number of shims required to offset the thermal misalignment.

        It is always a good idea to use the fewest shims under a foot as is practical. The more shims under a foot, the more likely the chance of creating a spring effect, or soft foot. If possible, make or use a single shim that is the total thickness required under the foot. If this is not possible, a maximum of four shims should be the limit, giving the foot a solid resting place and reducing the possibility of anything getting between individual shims.

        Make the necessary shim change, and tighten the bolts to their proper torque value. Then, repeat the process for the other side of the machine. Always tighten bolts to their prescribed torque on the first tightening to avoid any movement when working on the other side of the machine.

        When making shim changes for vertical alignment, shims must be placed beneath any shims already present to correct for soft foot. Placing shims used to correct vertical alignment on top of those used to prevent soft foot can create additional soft foot problems.

        Insert the shim all the way in until the shim slot bottoms out on the bolt. Then, pull the shim back about a quarter of an inch before tightening the bolt. If the shim is left inserted all the way into the threads, tightening the bolt will pinch the end of the shim, possibly affecting the accuracy of the shim change.

        After completing the shim changes and tightening the hold-down bolts, take another set of readings with the method used in the alignment calculation. If the move is within the specified tolerance, proceed with the horizontal moves. If a second vertical move is required, determine the necessary shim change and make the correction.

        Horizontal moves : Base plates installed with jack bolts are the easiest to move. In many situations, it is best to install jack bolts at the time of alignment rather than trying to move the machine some other more difficult and time-consuming way.

        Where no jack bolts are present, small hydraulic jacks can be used to move a machine if it is backed up to a solid structure such as a beam, solid wall, adjoining pedestal or base. A chain fall or come-along hoist also can be used. The machine must be secured to something solid or immovable and operated one click at a time.

        Another effective method is to use pony clamps or pipe clamps attached and operated to move the machine smoothly in the desired direction as shown below in Fig 3.

        Where jack bolts are installed, all must be loosened before loosening any of the hold-down bolts. There is no need to completely back off or remove the hold-down bolts because very little pressure is required on the jack bolt to move the machine horizontally.

        Constructing a graph to determine the position of the misaligned shaft will show exactly which direction to move the machine. Another way to avoid confusion is to look from the fixed component toward the movable component. Everything to the right — or three o’clock — position is in the positive direction. Everything to the left — or nine o’clock — position is in the negative direction.

        The preferred and most accurate method for measuring the horizontal move is to place dial indicators around the machine in the planes of the feet. It is important to position the indicators on the machine in the location used in the alignment calculation. This is usually the center of the hold-down bold and at the approximate shaft height.

        The procedure for performing a horizontal move on a machine is:

      • Position the base-mounted dial indicators in the location of the machine’s feet or at the point determined from the alignment calculation

      • Adjust the dials to zero

      • Move the machine in the proper direction by the determined amount, making sure all of the dial indicators agree

        • Once all horizontal moves have been completed, a final set of readings should be taken to verify both vertical and horizontal alignment. Occasionally, a horizontal move can change the machine’s vertical position. If another vertical move is required, recheck the horizontal alignment.

          The most important consideration throughout all of these steps is to maintain control of the machine. The most accurate and precise measurements can be lost in an instant with the wrong method or technique.

          The Bottom Line…

          Thermal movement is an often-overlooked factor in misalignment.

          Control and accuracy are the keys to proper alignment.

          A dial indicators is the most effective way to measure horizontal move.

          Author Information
          Bob Boyle is Director – Power Transmission Products for Applied Industrial Technologies. Boyle has more than 20 years of marketing, sales and management experience in the manufacturing and power transmission industry. He has a bachelor of science degree in industrial distribution from Texas A&M University.

          Engler: let Congress view manufacturing in person

          NAM president John Engler told Congress that it was important to permit Congressional staff tours of manufacturing facilities.

          “Since nearly all of these manufacturing facilities are located outside of Washington, D.C., it is necessary to travel to get to them,” he said. “Congressional staffs see and experience things they have never before seen and experienced, and return to Washington better able to advise Members on issues related to manufacturing.”

          Engler cited two examples of recent Congressional visits to factories in Illinois, and said that all such field trips take place during Congressional recesses and are approved beforehand by the House Committee on Standards of Official Conduct and the Senate Select Committee on Ethics.

          Recent legislation designed to curtail lobbying abuses have had a “chilling effect” on legitimate fact-finding missions. “The NAM was forced to suspend our educational trips for the remainder of the year due to a devastating drop in participation,” said Engler.

          “Globalization requires that elected leaders see firsthand how manufacturing facilities operate and what challenges they face from international competition,” Engler said. “I see it as an obligation for members of Congress and their staff to understand the economic sector that provides growth and stability for our nation’s economy. The only way to meet that obligation is to walk the plant floors and observe and learn how things are made in America.”

          USDA and DOE announce energy conference for October

          U.S. Department of Agriculture Secretary Mike Johanns and U.S. Department of Energy Secretary Samuel Bodman announced that the two agencies will co-host a national renewable energy conference to help create partnerships and strategies to accelerate commercialization of renewable energy industries and distribution systems. The conference, Advancing Renewable Energy: An American Rural Renaissance, is scheduled for October 10 — 12, 2006, in St. Louis.

          “Never has reducing our dependence on foreign oil been such a pressing issue,” Bodman said. “We have the will and the means to replace significant quantities of foreign oil with homegrown fuel. We are hopeful this conference will identify major impediments and critical pathways to get more domestically grown, renewable energy sources out of the laboratory and into consumers’ hands as soon as possible.”

          The conference will focus on elements of President Bush’s Advanced Energy Initiative, specifically biomass, wind and solar research and commercialization. USDA and DOE expect the conference to identify major impediments, review challenges and make recommendations to help accelerate renewable energy technology development; examine key incentives that would help promote certainty and reduce risk for investors and developers in the marketplace; and raise public awareness.

          Organizational happenings

          Kuka Robotics Corporation recently signed Les Machineries AutomaTech, Inc. of Quebec as its newest system partner, extending the company’s reach into the Canadian market. Les Machineries AutomaTech plans on using Kuka robots in wood product manufacturing application cells designed to increase small and medium-sized manufacturer’s efficiency.

          Applied Manufacturing Technologies, Inc. has reorganized its engineering group into four new practice areas. The new areas are: robot programming, digital processing and simulation, design services: mechanical and electrical, and advanced applications. The robot programming group will provide professional robot programming and startup services for most major process robots, including ABB, Kuka, Fanuc and Motoman, among others. The digital processing and simulation group will provide processing and simulation development, with services for most major robot models, human models and simulation engines involving robotic, ergonomic and discrete-event simulation. The design services group will provide 2D and 3D mechanical design on most major CAD platforms and electrical and controls design, startup and support for most major PLC and logic-controller brands. The advanced applications group will support laser scanning, industrial networking, machine vision, custom MMI/GUI interface development and simulation and robot support for painting applications.

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