How can you prevent or correct shaft misalignment in pump and fan installations?

1 Identify the type of misalignment

Before you can fix the problem, you need to diagnose it. There are two main types of misalignment: parallel and angular. Parallel misalignment occurs when the shafts are parallel but not on the same axis, creating a gap between the coupling faces. Angular misalignment occurs when the shafts are not parallel, forming an angle between the coupling faces. You can use a straight edge, a caliper, or a dial indicator to measure the misalignment and determine its type and severity.

2 Choose the alignment method

There are different methods to align shafts, depending on the accuracy, complexity, and cost required. The most common methods are rim and face, reverse dial indicator, and laser alignment. Rim and face is a simple and inexpensive method that uses a dial indicator mounted on the rim and face of the coupling to measure the misalignment. Reverse dial indicator is a more accurate and reliable method that uses two dial indicators mounted on opposite sides of the coupling to measure the misalignment. Laser alignment is the most advanced and precise method that uses a laser beam and a detector to measure the misalignment.

3 Prepare the equipment

Before you start the alignment, you need to prepare the equipment and ensure the safety of the operation. You need to disconnect the power supply, lock out and tag out the equipment, remove any guards or covers, and clean the coupling and the shafts. You also need to check the condition of the bearings, the coupling, the base, and the foundation, and replace or repair any damaged or worn parts. You need to loosen the bolts and nuts that hold the equipment in place, and make sure there is enough space to move the equipment as needed.

4 Perform the rough alignment

The rough alignment is the initial step to bring the shafts close to alignment before using the chosen method. You need to use a straight edge or a caliper to align the coupling faces visually, and adjust the position of the equipment by shimming or moving the base. You need to check the alignment in both horizontal and vertical planes, and repeat the process until the gap between the coupling faces is within the tolerance specified by the manufacturer or the industry standard.

5 Perform the final alignment

The final alignment is the final step to fine-tune the alignment using the chosen method. You need to follow the instructions and procedures of the method, and use the appropriate tools and equipment. You need to measure the misalignment in both horizontal and vertical planes, and adjust the position of the equipment by shimming or moving the base. You need to check the alignment after each adjustment, and repeat the process until the misalignment is within the tolerance specified by the manufacturer or the industry standard.

6 Verify and document the alignment

The verification and documentation of the alignment is the last step to ensure the quality and performance of the operation. You need to run the equipment at normal operating conditions, and check for any signs of vibration, noise, heat, or leakage. You need to use a vibration analyzer or a thermographic camera to measure the vibration and temperature levels, and compare them with the baseline values. You need to record the alignment results, the adjustments made, the tools and equipment used, and any observations or recommendations for future maintenance.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?