Why Alignment

Reliability starts with precision shaft alignment

Up to 50% of damage to rotating machinery is directly related to misalignment! Well aligned machines reduce operating costs!

Reliability starts with precision shaft alignment

Extend machine availability and efficiency

Precision alignment pays back Rotating machinery is susceptible to misalignment. Machines that are well aligned at the commissioning stage and thereafter regularly maintained, will in the long term reduce both plant operating and maintenance costs. Laser precision alignment extends machine availability as the Mean Time Between Failure (MTBF) increases. It protects assets and increases product quality, as vibration is reduced to very low levels. When misaligned, the loading of the shafts dramatically increases due to the reaction forces created within the coupling. Precision alignment guarantees:

 Reduced energy consumption  Reduction in bearing, seal, shaft and

coupling failure

 Reduced bearing and coupling

temperatures

 Reduced vibration  No breaking (or cracking) of shafts  Secure foundation bolts

The effect of increased coupling loading due to

Accurate shaft alignment contributes in more than one way towards great savings and a cleaner environment.

misalignment can readily be shown using infrared thermography. 1. In this case, the flexible

1. Out of tolerance

2. Within tolerance

coupling element heats up. The machine develops elevated temperatures, particularly around the bearing housings. 2. Precision alignment drastically reduces factors that may cause machinery breakdown.

PRFTECHNIK Alignment Systems

3 benefits of precision alignment

Variation of power consumption % 10 8 Reduction in power consumption

1. Reduced energy consumption Effects on power consumption Significant power savings can be made through accurate alignment. Precise alignment eliminates reaction forces and reduces energy consumption by up to 10 %.
Courtesy of ICI PLC

- 10%

6 4 2 0

0,25

0,50

0,75

1,00

1,25

1,50

Offset in mm

2. Reduced repair incidences Mechanical seal repairs Mechanical seal repairs decline by up to 65 % when precision alignment is carried out on a regular basis.
Courtesy of HOECHST AG Gendorf / Germany

Number of mechanical seal repairs 55 50 45 40 35 30 25 20 15 1 2 3 4 years Reduction in seal repairs

- 65%

Number of pump repairs

Pump repairs The rate of repairs declines by up to 30% when precision laser alignment becomes an integral part of the pump repair schedule. Maintenance costs are also reduced through lower parts expense and inventory levels.
Courtesy of HOECHST AG Gendorf / Germany

100 90 70 50 45 35 25 15 1 2 3 4

Drop in pump repairs

- 30%

years

3. Longer machine life Relation between offset and bearing life cycle The smaller the offset misalignment, the higher the expected bearing life cycle.
Courtesy of The University of Tennessee

Bearing life cycle (%)

90

Increase in bearing life cycle

70

50

+50%

0,25

0,50

0,75

1,00

Offset (mm)

Align machines to specified tolerance move

A survey conducted by one of the worlds leading rotating equipment service organizations shows that less than 10% of the 160 machines randomly chosen for measurement were found to be aligned within acceptable limits. Offset (mm) 0.00 0.05 0.06 0.10 0.11 0.20 0.21 0.50 0.51 1.00 > 1.00
Only 7% of the measured machines fall within the acceptable alignment tolerances.

Machines measured (%) 7% 10 % 23 % 31% 18 % 11 % out of tolerance acceptable alignment

The above tolerances are for equipment running at 3000 rpm.

Statistics courtesy of a major UK chemical company

Reliability starts with precision shaft alignment

Traditional shaft alignment methods

Conventional measurement methods possess a low resolution for the adjustment of modern machinery. The straightedge/feeler gauge methods depend on the limited resolution of the human eye. The resulting resolution of 1/10 mm is for most machinery inadequate. Dial indicators normally have a resolution of 1/100 mm, but calculations tend to be complicated, requiring highly experienced users, and jobs take longer to accomplish. These methods are prone to human influences when reading dial indicator values or computing the alignment condition.

How accurate are dial indicator readings?

Sagging indicator brackets Sag should always be measured before actual alignment readings are taken irrespective of how solid the bracket appears.

45 5 40 10 35
15

0
45

5
40

10

35

30

20

15

25

25

20

30

Low resolution Up to 0.005 mm rounding error may occur with each reading which easily results in an error of up to 0.04 mm in the calculated results.

Sticking/jumping dial hands Sometimes the indicator must be tapped in order for the needle to settle on its final value.
35

45 5 40 10
15 20

45

5
40

10 15

35 30

30

25

25

20

Play in mechanical linkages Slight amounts of looseness may not be noticed, yet produce large errors in results.

Reading errors Human errors occur all too often when dials must be read under cramped, poorly-lit conditions and severe time constraints.

Tilted dial indicator The indicator may not be mounted perpendicular to the measurement surface so that part of the displacement reading is lost.

Axial shaft play This can affect face readings taken to measure angularity unless two axially mounted indicators are used.

PRFTECHNIK Alignment Systems

Advantages of laser shaft alignment

Straightforward alignment procedure Dimensions  Systems are user-friendly and intuitive

 Quick set-up of the fully assembled readyto-use sag-free brackets

 Follow the simple on-screen guidance to

enter required machine data.
Unibeam

 Bracket variety for any shaft or coupling

Measure  Error-free and accurate measurement with a resolution of 1 micron (0.00004)

 No human reading errors and bracket sag

influences

 Quick on-screen laser beam adjustment  Take readings at any desired position
Results  Instant display of the coupling & feet values in both horizontal and vertical directions

Sweep mode

 Evaluation of the alignment condition

according to coupling tolerance

 Repeatability of results  Reports generated directly from instrument,

in conformity with ISO 9001 requirements

TolChek

Live move

The unique measurement principle offered by PRFTECHNIK laser alignment systems allows the machine feet corrections to be monitored during live adjustment. The machine graphics show the direction and the correction value of feet to be moved. A smiley face appears as soon as the alignment condition falls within the set coupling tolerances. PERMABLOC precut shims from PRFTECHNIK are the quality shims for fast and accurate alignment correction.

Reliability starts with precision shaft alignment

Benefits of PRFTECHNIK laser alignment systems

Continuous sweep mode Measurement data is automatically and continuously collected from any start position as the shafts are rotated capturing a large number of measurement points to accurately determine the alignment condition. Tolerances (TolChek) Avoid unnecessary moves by automatically evaluating alignment condition with respect to tolerances using the smiley which is also active during live machine correction. Soft foot For good alignment, soft foot must be eliminated. The machine feet should rest properly on the foundation. Soft foot is measured, corrected and documented. Base-bound or bolt-bound Problems arising from base-bound or bolt-bound feet are resolved by redefining fixed/movable feet. Thermal growth and Target specifications The specifications can be input to take into account the expected positional change of the machine during operation. Choose coupling type Short flex, single plane, cardan or spacer couplings can be selected to apply the correct tolerance and display criteria for your machines. InfiniRange The measurement range of the detector can be infinitely extended to accommodate gross misalignment. This is ideal to perform and document initial rough alignment and easily handle long spans across spacer shafts. Machine train alignment Measure and display the entire alignment condition of machine train; allowing the user to make the optimal machine adjustment.

PRFTECHNIK Alignment Systems

We care about your assets

PRFTECHNIK Alignment Systems, the inventor of laser shaft alignment, has more than 25 years of experience in developing, manufacturing and applying laser-based alignment measurement systems. We offer a full range of shaft alignment products. These modular systems can be customized to include advanced functions to meet user needs. They are also available in intrinsically safe versions for use in hazardous areas. Our measurement systems are used in many alignment applications of rotating machinery in most industries.

ALIGNMENT CENTER The software for professionals

ALIGNMENT CENTER is a state-of-the-art PC software database platform for all PRFTECHNIK Alignment instruments and applications. It is the perfect solution for preparing, analyzing, organizing and archiving measurements. Measurement related data is also saved and the measurement history can also be followed and organized under hierarchies. The software generates professional color reports that include photos, company information and logo.

... shafts and much more

Applications PRFTECHNIK Alignment measurement systems are utilised in a wide range of industrial applications including alignment of rotating machinery, bores, turbines and rolls, monitoring of machine position changes, measurement of machine tools, surface flatness and straightness.

Industries PRFTECHNIK hi-tech instruments are used in top industrial organizations worldwide. Industrial sectors covered include: power, oil, gas, mining, petrochemical, cement, water treatment and sewage, marine and shipping, pulp and paper, chemical and pharmaceuticals, food processing, steel, production and processing, and within OEMs.

PERMABLOC, InfiniRange, UniBeam and TolChek are registered trademarks of PRFTECHNIK Dieter Busch AG. No copying or reproduction of this information, in any form whatsoever, may be undertaken without express written permission of PRFTECHNIK AG. The information contained in this leaflet is subject to change without further notice due to the PRFTECHNIK policy of continuous product development. PRFTECHNIK products are subject to patents granted or pending throughout the world. Copyright 2010 by PRFTECHNIK Alignment Systems

A member of the PRFTECHNIK Group

Printed in Germany ALI 9.100.02.10.G

PRFTECHNIK Alignment Systems GmbH Freisinger Str. 34 85737 Ismaning Germany Tel +49 89 99616-0 Fax +49 89 99616-100 [email protected] www.pruftechnik.com