COULPING & ALIGNMENT

Dr.M.E.Kassab Eng. M.Ajmal

Department of Mechanical Engineering technology
YANBU INDUSTRIAL COLLEGE
 COUPLINGS

ØConnect two shafts in same line

ØTransmit power(torque)
ØRotate at same RPM, same direction of rotation.
ØDirect connection b/w driver n driven

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 2
 Single flexible coupling
Load

Driver

Floating shaft torque sensor

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 3
 TYPES OF COUPLINGS

1. Rigid Coupling
Features:
Don’t allow misalignment (angular and parallel)
Good for unsupported and overhung shafts
2. Flexible Couplings

a) Material Flexing
b) Mechanical Flexing

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 4
 RIGID COUPLINGS

Flange Split Sleeve

d

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 5
 Flanged Coupling

A key is used to to fix the coupling to the shaft,

and then couplings are bolted together.

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 6
 Split Sleeve

Again, a key is used to fix the coupling and the shaft

and the two halves of the coupling are bolted
together.

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 7
 MATERIAL FLEXING

Spider coupling

Pin and bush coupling Jaw coupling

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 8
 Disc coupling

Rubber gear coupling

Tire coupling

Oldham coupling
Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 9
 Rubber gear coupling

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 10
 MECHANICAL FLEXING

Helical coupling
Universal Joint

Bellows coupling Grid coupling

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 11
 Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 12
 SPECIAL COUPLINGS

Magnetic coupling Hydraulic coupling

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 13
 Universal Joint

•Consist of two end yokes and a center bearing block.

•Provides for angular misalignment of up to 45 degrees.
Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 14
 COMPARISON BETWEEN RIGID AND FLEXIBLE COUPLINGS

RIGID FLEXIBLE
Ø Limited Application Ø Vast Application
Ø Don’t tolerate misalignment Ø Some misalignment tolerable
Ø Simple to Manufacture Ø Not easy to manufacture
Ø Less Cost Ø Usually Costly
Ø Transmit more power Ø Comparatively less power Transmission
Ø More Stress on bearings Ø Bearing Friendly

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 15
 ALIGNMENT

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 16
Causes of Excessive Vibration
 Some Benefits of Precision Alignment

• Reduced vibration amplitudes

• Improved product quality
• Longer bearing life
• Longer seal life
• Less unscheduled downtime
• Some have seen lowered energy consumption

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 18
 Rotational Centers

All shafts, whether they are straight or bent,

rotate on an axis called the rotational center.
The rotational center forms a straight line.

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 19
 Co-linearity

Two shafts are said to be collinear when their

respective rotational centers form a single line.

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 20
 Misalignment

Shafts are misaligned when the two

shafts are not colinear.

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 21
 Stationary & Movable Machines
The driven component is usually designated as the
stationary machine, the driver as the movable
machine.
Therefore, misalignment is expressed by
describing the position of the movable machine
relative to the stationary machine.
Stationary Machine Movable Machine

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 22
 ALIGNMENT BASICS

The lack of alignment, or misalignment, is a condition where the rotating

centerlines of two or more machinery shafts are not in line with each other.

§ Parallel Misalignment

§ Angular Misalignment

§ Combination
Misalignment

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 23
 Types of Misalignment

Offset misalignment is often thought of as two

coupling hubs which are offset vertically or
horizontally.

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 24
 Horizontal Misalignment

Machines may be misaligned horizontally...

Top view(plan)

right

left

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 25
 Vertical Misalignment
... or vertically.

Side view(elevation)

high

low

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 26
 Angular misalignment

Angular misalignment is often thought of as two

coupling faces which are not parallel.

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 27
 Angular Misalignment

Angular misalignment is centerline deviation

where the offset is not constant.

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 28
 MISALIGNMENT SYMPTOMS

1. Premature bearing, seal, shaft, or coupling failures.

2. Elevated temperatures at or near the bearings.
3. Excessive amount of lubricant leakage.
4. Elastomeric powder seen in the coupling shrouds.
5. Similar pieces of equipment seem to have a longer operating life.
6. Unusually couplings wear quickly.
7. The shafts are breaking (or cracking)
at or close to the inboard bearings or coupling hubs.
8. Excessive amounts of grease (or oil)
on the inside of the coupling guard.
9. Loose foundation bolts.
10. Loose or broken coupling bolts.

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 29
 BENEFITS OF PRECISION ALIGNMENT

§ Improve plant operating life and reliability

§ Reduce costs of consumed spare parts such as seals and bearings
§ Reduce maintenance labor costs
§ Improve production plant availability
§ Reduce production loss caused by plant failure
§ Reduce the need for standby plant
§ Improve plant operating safety
§ Reduce costs of power consumption on the plant
§ “Push” plant operation limits in times of production need
§ Obtain better plant insurance rates through better operating practice
and results

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 30
 FOR EXAMPLE

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 31
 MISALIGNMENT TOLERANCES

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 32
 Alignment Methods
§ Eyesight – straightedge and feeler gauges
§ Dial indicators – mechanical displacement gauges
§ Laser optic alignment systems.

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 33
 Alignment Methods

EYESIGHT METHOD

Features:
§ Mostly used with flexible couplings
§ Cheap and easy to use
§ Limited accuracy due to human eye resolution 0.1mm

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 34
 DIAL INDICATORS METHOD

§ Face and Rim Method Tools Required

§ Reverse Indicators Method dial indicators 2/3, meter tape, shims,
§ 3-Indicators Method calculator, graph paper, vernier caliper

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 35
 FACE AND RIM METHOD

D= Working diameter of coupling

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 36
 1.Take a pipe
2.Fix the bracket to the pipe
Dial indicator positioning
3.Fix the dial gauge to the bracket
4.Adjust the dial gauge to zero
5.Rotate the dial gauge to 180 degree
6.Take the reading of the dial gauge
7.The difference in the reading is the sag reading

Field reading-sag reading=compensated reading

Dial indicator bracket sag

measurement

The reading which we get from dial gauge is called field reading
Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 37
 Apply Validity Rule
T+B = L+R

If dial readings are not valid then

1. Human error
2. Coupling is oval
3. Damaged bearings
Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 38
 Sag values
Example #1

Field
Rim Readings
Readings T
0.0

0.0

L +0.59 -0.26 +0.04 +0.27 R

-0.22

Face Readings +0.86

B

Compensated
Readings
Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 39
 T
Make right side 0.0
readings zero

0.0

Rim readings show parallel and Face

readings show angular misalignment

L +0.63 -0.25 +0.05 +0.31 R

-0.31 -0.05 -0.05 -0.31
+0.32 -0.30 0.0 0.0

T
-0.20
0.0 Final set of
readings

+0.94 0.0
B

L +0.32/2 -0.30 +0.0 +0.0 R

For horizontal
alignment Divide rim -0.20
readings by 2

For vertical alignment +0.94/2

B

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 40
 Vertical Alignment

0.0

0.0

-0.20

+0.47
T

0.47

B
-0.20

By comparing similar triangles calculate the values of x1 and x2

100

100 Front foot shim thickness =s1= 0.47-x1

100 Back foot shim thickness = s2 = 0.47-x2

-0.20 -0.20 Rotate this triangle by 900

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 41
 REVERSE INDICATOR METHOD

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 42
 VERTICAL ALIGNMENT
RULE: 1- driven m/c readings: +ve up & -ve down
2- driver m/c readings : opposite signs same
side

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 43
 HORIZONTAL
ALIGNMENT
RULE: 1- the side which is zero draw on top
2- driven m/c readings: +ve up & -ve down
3- driver m/c readings : opposite signs same
side

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 44
 Laser Alignment System

ADVANTAGES OF LASER ALIGNMENT

1. Precision alignment with no manual input of data and no graphical or numeric calculations to perform.
2. Graphic display of alignment results .
3. No mechanical fixtures - no bracket sag.
4. No need to disassemble the coupling to effect an alignment.
5. No need to take readings at predetermined locations such as12;00, 3;00, 6;00 and 9;00 o’clock. Results
can be obtained with less than 90 degrees of shaft rotation.
Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 45
 Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 46
 SPECIAL ALIGNMENT

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 47
 FIELD READING-(-SAG READING)=COMPENSATED READING.
SAG VALUES ARE THE ONE WHICH IS TAKEN BECAUSE THE DIAL
INDICATOR IS FIXED TO BRACKET .

INITIALLY THE COUPLING MAY BE MISALIGNED WE ARE NOT

TAKING THAT READING BUT WHEN WE ROTATE TO 1800 THE DIAL
INDICATOR MAY NOT TOUCH THE COUPLING BECAUSE OF THE
WEIGHT OF THE BRACKET,SO IN ORDER TO COMPENSATE THAT
WE WILL FIND COMPENSATE READING BY SUBTRACTING SAG
VALUE FROM FIELD READING. FIELD READING ARE THE ONE
WHICH WE TAKE FROM DIAL GAUGE .

THE SAG VALUE READING IS FIXED THAT WE CALCULATED

ALREADY SO WE WILL GIVE U THE SAG VALUE NO NEED TO
SEARCH FOR SAG VALUE IT WILL BE GIVEN ALONG WITH FIELD
VALUE.

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 48
 FIELD VALUE:

COMPENSATED VALUE : THIS IS GOT FROM THE RULE

FIELD READING-(-SAG READING)=COMPENSATED READING.

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 49
 NOW FIRST CALCULATE THE VERTICAL READING HORIZONTAL
READING U CAN CALCULATE LATER.
RIM READING SHOULD BE DIVIDED BY 2 BECAUSE OF THE SAG
VALUE ( WE HAVE NOT TAKEN THE READING INTIALLY WE SET TO
ZERO )THERE WILL BE SOME READING BUT WE ARE NOT
CONSIDERING THAT WE HAVE MADE ZERO AND WHEN WE ROTATE
TO 180 DEGREE IT WILL BECOME DOUBLE READING SO WE HAVE
TO DIVIDE BY 2

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 50
NEXT STEP: WE NEED TOTAL 11 READING TO SOLVE THE PROBLEMS
1 TO 8 READINGS WE ARE GETTING FROM DIAL GAUAGE(i-e top 2 reading bottom 2 reading left 2 reading right 2
reading so total 8 reading )we need still 3 reading we will get this from

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 51
 Step 1 : first draw a horizontal line
Step 2: consider any one fixed other rotating here we consider pump fixed because we cant adjust pump
because it is connected to pipe connection and many things that will get disturb so better take motor
which is not connected to many parts.+0.47 we are getting positive reading means plunger went inside
.it mean that end came down so it should be below the centre line(0.47 should be below the centre line).

now if we see the face reading it is showing -0.2 it has moved at an angle

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 52
 100 is the rim diameter. it has moved to an angle so we will use the rule to calculate tan Ɵ.

WE ARE GOING TO ROTATE TO 90 DEGREE SO THAT WE CAN DRAW ON HORIZONTAL LINE.

THIS PART IS DRAWN ON THE

HORIZONTAL LINE

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 53
 AFTER THIS NOW EXTEND THE LINE
TO THE HORIZONTAL LINE

NOW WE HAVE TO FIND X1 AND X2 BY USING THE RULE SHOWN BELOW

tan Ɵ=opp/adjacent.
tan Ɵ=0.2/D=X1/A=X2/A+B NOW COMPARE AND CALCULATE X1
AND X2
0.2/D=X1/A
SIMILARLY
0.2/D= X2/A+B
X1 IS THE FRONT FOOT BECAUSE THE ONE WHICH IS NEAR TO THE
COUPLING IS FRONT FOOT THE ONE WHICH IS FAR FROM THE
COUPLING IS BACK FOOT SO X2 IS BACK FOOT.

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 54
 Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 55
 1.Write at least three methods for shaft alignment
•PARALLEL
•ANGULAR
•COMBINATION
2) Write the procedure to determine the sag values of a bracket with reference to shaft
alignment using dial indicators. Also select the tools/parts required for it from the given
below;
Tool/Part Required or not Tool/Part Required or not
1 Meter tape 6 Hammer
2 Bracket * 7 Pipe *
3 Shaft 8 Coupling *
4 Dial indicator * 9 Shims
5 Feeler gauge V-Blocks *

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 56
 Procedure:
•Put pipe on v bloks
•Install bracket on pipe
•Install dial indicator on bracket
•Turn it to 180 degree to get sag

3) Write any two features of flange shaft couplings

1.Don’t allow misalignment (angular and parallel)
2.Good for unsupported and overhung shafts

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 57
 Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 58
 1.Write the names of any two special shaft couplings.
•Magnetic coupling
•Hydraulic coupling

2.Write the names two alignment methods in which dial indicators are used.
•Reverse indicator method
•Face and rim method

Dr.M.E.Kassab
Department of Mechanical Engineering technology
YIC/ MET213 / Dr.Kassab/ YANBU INDUSTRIAL COLLEGE COUPLING & ALIGNMENT 59