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How do you optimize pump alignment and balance?

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Pump alignment and balance are crucial factors for the performance and reliability of rotating equipment in industrial applications. Misalignment and imbalance can cause excessive vibration, noise, wear, and energy consumption, leading to reduced efficiency, increased maintenance costs, and potential failures. In this article, you will learn how to optimize pump alignment and balance using some basic tools and techniques.

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Akash Shrivastava, PhD

PhD - IIT Kgp | Remote Condition Monitoring | Automated Analytics
Ronald Frend

VP Technical – NetZero & Renewables
SAAD AHIZOUN ??

Driving Operational Excellence in Manufacturing through Lean Practices- industrial Engineer -LSSBB -PMEC -ScrumFC

1 What is pump alignment and balance?

Pump alignment refers to the adjustment of the relative position and orientation of the pump and the motor shafts, so that they are in a straight line and parallel to each other. Pump balance refers to the distribution of mass and forces on the rotating parts of the pump, such as the impeller, shaft, and coupling, so that they do not create any unbalanced forces or moments that cause vibration. Both pump alignment and balance depend on the design, installation, operation, and maintenance of the pump system.

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SAAD AHIZOUN ??

Driving Operational Excellence in Manufacturing through Lean Practices- industrial Engineer -LSSBB -PMEC -ScrumFC
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L'alignement de la pompe concerne la position correcte de ses composants rotatifs, assurant une transmission efficace de l'énergie. L'équilibrage ajuste la répartition de la masse pour minimiser les vibrations, garantissant ainsi la fiabilité et la performance optimale de la pompe.

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2 Why is pump alignment and balance important?

Pump alignment and balance are important for several reasons. First, they affect the pump efficiency and performance, as misalignment and imbalance can increase friction, reduce flow, and create pressure losses. Second, they affect the pump life and reliability, as misalignment and imbalance can cause premature wear and tear, fatigue, and damage to the pump components, such as bearings, seals, couplings, and casings. Third, they affect the safety and environmental impact of the pump system, as misalignment and imbalance can generate excessive heat, noise, and vibration, which can pose hazards to the workers and the surroundings.

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Akash Shrivastava, PhD

PhD - IIT Kgp | Remote Condition Monitoring | Automated Analytics
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An often overlooked concern is the impact of misaligned and unbalanced pumps (, and other mechanical issues ) on energy consumption. When pumps operate without optimal alignment and balance, increased friction leads to higher energy consumption. Proper alignment and balance are critical for minimizing resistance, allowing machines to run more efficiently and reducing the overall power required. Addressing misalignment not only enhances energy efficiency but also extends the lifespan of the equipment, highlighting the significance of routine maintenance in optimizing industrial processes and minimizing energy costs.

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Ronald Frend

VP Technical – NetZero & Renewables
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Misalignment causes additional stresses in the shaft that (in extreme cases) causes shaft fatigue failure. Even if the shaft survives, the bearings on either side of the coupling will be affected and will have a shorter life. Don't believe the salesman who tells you his coupling will handle misalignment - those couplings simply transfer the forces to bearings either side of the coupling. Balance puts additional load on bearings and will cause failure of the lubrication on rolling element bearings. e.g. pillow block bearing on a cement fan had failures every time the unbalance passed 10mm/s RMS. Cause was bearing load squeezing out the grease from between ball & race. Solution was to clean the fan just as unbalance reached 10mm/s.

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SAAD AHIZOUN ??

Driving Operational Excellence in Manufacturing through Lean Practices- industrial Engineer -LSSBB -PMEC -ScrumFC
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L'alignement et l'équilibrage des pompes sont essentiels car ils assurent une transmission efficace de l'énergie, prolongent la durée de vie des composants, réduisent les vibrations, maintiennent des performances optimales, et contribuent à des co?ts de maintenance réduits.

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3 How do you measure pump alignment and balance?

Different methods and instruments can be used to measure pump alignment and balance, depending on the pump system's type, size, and condition. Dial indicators are devices that measure the displacement of a pointer attached to a spring-loaded arm that contacts the surface of the rotating part. They can be used to detect radial and axial runout, angular and parallel misalignment, and dynamic imbalance of pump shafts and impellers. Laser alignment tools use laser beams and sensors to measure the relative position and orientation of the pump and motor shafts and are more accurate and faster than dial indicators. They can also measure thermal growth and soft foot of the pump system. Vibration analyzers measure the frequency, amplitude, and phase of vibration signals generated by the rotating parts of the pump system. This allows for diagnosing root causes, severity of misalignment or imbalance, as well as other defects or faults.

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SAAD AHIZOUN ??

Driving Operational Excellence in Manufacturing through Lean Practices- industrial Engineer -LSSBB -PMEC -ScrumFC
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Pour mesurer l'alignement et l'équilibre de la pompe : Alignement : Utilisez des outils tels que des lasers d'alignement ou des instruments de mesure précis pour vérifier la position parallèle de l'arbre de la pompe et celui du moteur. équilibrage : Employez des techniques d'équilibrage, comme l'ajustement des masses sur l'impulseur, et des instruments de mesure des vibrations pour garantir un fonctionnement fluide et équilibré. En résumé, utilisez des outils spécialisés pour mesurer l'alignement et des méthodes d'équilibrage appropriées pour assurer un fonctionnement optimal de la pompe.

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4 How do you correct pump alignment and balance?

There are various procedures and techniques to correct pump alignment and balance, depending on the type, size, and condition of the pump system. Shimming involves adding or removing thin metal pieces under the feet of the pump or motor to adjust their height and level, which can help to correct parallel misalignment, soft foot, and thermal growth. Moving entails shifting the position of the pump or motor along the horizontal or vertical axis to adjust their alignment, which can help to correct angular misalignment and offset. Lastly, balancing involves adding or removing mass from the rotating parts of the pump system to adjust their balance, which can help to correct static and dynamic imbalance.

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Jonathan Lawrence

Operations Manager
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Quite often when a pump is installed and aligned thermal growth plays a large part in future misalignment. The parts will be offline for periods whilst replacement work are carried out and are rarely at operating temperature when aligned. A good VA system will flag this but more often than not the need to catch up the downtime already lost outweighs the need to switch everything back off once it at at temperature to recheck the alignment and adjust as necessary with too much faith being left the the VA system to find it.

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5 How do you maintain pump alignment and balance?

Maintaining pump alignment and balance depends on the type, size, and condition of the pump system. It is important to follow the manufacturer's instructions and specifications for installation, operation, and maintenance. Regular inspections and checks of the pump system components should be conducted, with any necessary replacements or repairs made. The proper tools and techniques should be used for alignment and balance measurement and correction, with results and actions taken documented. Additionally, pump system vibration, noise, temperature, and power consumption should be monitored and analyzed to identify and resolve any issues or anomalies. External factors that can affect the pump system alignment and balance such as pipe strain, foundation settlement, thermal expansion, or load changes should be avoided.

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Ronald Frend

VP Technical – NetZero & Renewables
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Pumps do not usually go out of alignment during normal operation. Misalignment happens when the driver has been moved and that is usually after maintenance. Always check alignment after any pump or driver work that involves moving the driver or the pump. API 686 requires the pipe length connected to the pump should not be fully fabricated off-site but have the pump flanges welded on site to minimise piping strain. Alignment gear should be kept on the pump while the pump piping is attached to identify piping strain that causes misalignment. During normal operation use velocity vibration to identify 1x (plus harmonics sometimes), especially in the axial direction - a classic indicator of misalignment. Also consider hot alignment.

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6 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?

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How do you optimize pump alignment and balance?

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4

5

6

1 What is pump alignment and balance?

2 Why is pump alignment and balance important?

3 How do you measure pump alignment and balance?

4 How do you correct pump alignment and balance?

5 How do you maintain pump alignment and balance?

6 Here’s what else to consider

Industrial Engineering

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How do you optimize pump alignment and balance?

1

2

3

4

5

6

1 What is pump alignment and balance?

2 Why is pump alignment and balance important?

3 How do you measure pump alignment and balance?

4 How do you correct pump alignment and balance?

5 How do you maintain pump alignment and balance?

6 Here’s what else to consider

Industrial Engineering

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