3rd Edition

Shaft Alignment Handbook

By John Piotrowski, John Piotrowski Copyright 2006
    862 Pages 32 Color & 879 B/W Illustrations
    by CRC Press

    Rotating machinery is the heart of many industrial operations, but many engineers and technicians perform shaft alignment by guesswork or with limited knowledge of the tools and methods available to accurately and effectively align their machinery. Two decades ago, John Piotrowski conferred upon the field an unprecedented tool: the first edition of the Shaft Alignment Handbook.

    Two editions later, this bestselling handbook is still the most trusted and widely embraced guide in the field. The third edition was reorganized, updated, and expanded to be more convenient, intuitive, and to reflect the latest developments in the area. Dedicated chapters now discuss the basics of alignment modeling, each of the five basic alignment methods, and electro-optic methods. Significant new material reflects recent findings on detecting misalignment, machinery movement from offline to running conditions, multiple element drive trains, and specific information on virtually every type of rotating machinery in existence. Entirely new chapters explore bore and parallel alignment.

    Providing detailed guidance based on years of hands-on experience, the Shaft Alignment Handbook, Third Edition is a practical tool to help avoid costly shutdowns, dangerous failures, and early replacements.

    INTRODUCTION TO SHAFT ALIGNMENT
    Benefits of Good Machinery Alignment
    Consequences of Defective Alignment
    Four Basic Ingredients Necessary to Insure Alignment Success
    Eight Basic Steps to Align Machinery
    How Qualified Are You to Detect and Correct Machinery Misalignment?
    Why Should People Be Tested on Their Alignment Skills?
    Experience Evaluation for Machinery Alignment
    Who Needs to Be Trained and Qualified in Shaft Alignment?
    Assessing a Person's Knowledge and Experience Level in Shaft Alignment
    Alignment Qualification or Certification Testing
    Periodic Alignment Checks
    Alignment Record Keeping
    References
    DETECTING MISALIGNMENT ON ROTATING MACHINERY
    The Four Maintenance Philosophies
    Types of Forces that Occur on Rotating Machinery
    Bibliography
    FOUNDATIONS, BASEPLATES, INSTALLATION, AND PIPING STRAIN
    Varying Composition of Earth's Surface Layer
    How Do We Hold This Equipment in Place?
    Problems to Look for in Your Foundations and Baseplates
    Checking for Excessive Static Piping Forces on Rotating Equipment
    Visual Inspection Checklist
    How Long Will Rotating Machinery Stay Accurately Aligned?
    References
    FLEXIBLE AND RIGID COUPLINGS
    Coupling and Shaft Misalignment Tolerances-What is the Difference?
    The Role of the Flexible Coupling
    What to Consider When Specifying a Flexible Coupling
    Types of Flexible Couplings
    Rigid Coupling Design
    Flexible Coupling Lubrication
    Coupling Installation
    Coupling Hub Attachment Methods
    Keys and Keyways
    Bibliography
    PRELIMINARY ALIGNMENT CHECKS
    Foundation and Base Plate Checks
    Dial Indicator Basics
    Damaged, Worn, or Improperly Installed Machinery Component Checks
    Runout
    Machine Housing to Base Plate Interface Problems
    Verifying that the Soft Foot Has Been Eliminated
    Other Methods for Correcting Soft Foot Problems
    SHAFT ALIGNMENT MEASURING TOOLS
    Dimensional Measurement
    Classes of Dimensional Measurement Tools and Sensors
    Sweeping 90° Arcs Twice to Measure a Misalignment Condition
    Why Measurements Are Taken at 90° Intervals
    Rotating Both Shafts to Override a Runout Condition
    Tips for Getting Good Alignment Measurements
    Engaged Couplings Will Produce Measurement Errors
    Rim Indicator Setup Variations
    Rim Readings Indicate Twice the Centerline Offset
    Validity Rule
    Partial Arc Mathematics
    Bracket or Bar Sag
    Xmas Tree Brackets and Face Sag
    Zero Sag Brackets
    Dial Indicator Shaft Alignment System Manufacturers
    Dial Indicator Manufacturers Hardware Specifications
    Bibliography
    CORRECTING MISALIGNMENT
    Installing Machinery for the First Time
    Bolt-Bound Conditions
    Last Resort Measures for Bolt-Bound Conditions
    Machinery Positioning Basics
    Types of Movement Tools
    What to Do When Things Are Not Working
    Misalignment Rantings
    Bibliography
    ALIGNMENT MODELING BASICS
    Graphing and Modeling Alignment Techniques
    Basic Alignment Models
    Scaling the Drive System onto the Alignment Model
    Cardinal Alignment Graphing and Modeling Rules
    Bibliography
    DEFINING MISALIGNMENT: ALIGNMENT AND COUPLING TOLERANCES
    What Exactly Is Shaft Alignment?
    Does Level and Aligned Mean the Same Thing?
    Measuring Angles
    Types of Misalignment
    Definition of Shaft Misalignment
    Checking the Misalignment Tolerance
    Shaft versus Coupling Alignment
    How Straight Are Rotating Machinery Shafts?
    REVERSE INDICATOR METHOD
    Basic Mathematical Equations for the Reverse Indicator Method
    Modeling Reverse Indicator Method Using the ''Point-To-Point'' Technique
    Rim Readings Are Always Twice the Offset Amount
    Modeling the Reverse Indicator Method Using the Line-To-Point Technique
    Bibliography
    FACE AND RIM METHODS
    Mathematical Relationship in Machinery Alignment
    Sixteen-Point Method
    Twenty-Point Method
    Problems with Taking Face Readings
    Modeling the Face and Rim Method
    Artificial Face Surface
    References
    DOUBLE RADIAL METHOD
    Basic Mathematical Equations for the Double Radial Method
    Modeling the Double Radial Method
    SHAFT TO COUPLING SPOOL METHOD
    Basic Mathematical Equations for the Shaft to Coupling Spool Method
    Modeling the Shaft to Coupling Spool Method
    FACE-FACE METHOD
    Basic Mathematical Equations for the Face-Face Method
    Modeling the Face-Face Method
    ELECTRONIC AND ELECTRO-OPTICAL SHAFT ALIGNMENT SYSTEMS
    Optical Encoder System
    Laser-Detector Systems
    Laser System Manufacturers Hardware Specifications
    Laser System Manufacturers Software Specifications
    References
    MEASURING AND COMPENSATING FOR OFF-LINE TO RUNNING MACHINERY MOVEMENT
    What Type of Machinery Is Likely to Change Equipment's Position When Running?
    What Causes Machinery Movement to Occur?
    Conducting the Off-Line to Running Machinery Movement Survey
    Taking "Hot" Alignment Measurements Immediately after Shutdown
    Four General Categories of OL2R Measurements
    Calculating Machine Case Thermal Expansion Using the Strain Equation
    Inside Micrometer-Tooling Ball-Angle Measurement Devices
    Vertical, Lateral, and Axial OL2R Movement
    Proximity Probes with Water-Cooled Stands
    Optical Alignment Equipment
    Optical Parallax
    Using Optical Tooling for Measuring Machinery Movement
    Establishing Reference Planes
    Alignment Bars with Proximity Probes
    Applying Laser-Detector Systems for OL2R Measurements
    Ball-Rod-Tubing Connector System
    Vernier-Strobe System
    Instrumented Coupling Systems
    Aligning Shafts for Running Conditions (Also Known as Running Alignment or ''Hot Operating Alignment'')
    Bibliography
    ALIGNING MULTIPLE-ELEMENT DRIVE SYSTEMS
    Multiple-Element Drive Train Alignment Laws
    Multiple-Element Drive Train: Graphing and Modeling Techniques
    Multiple-Element Drive Train Modeling-One Set of Shafts at a Time
    Multiple-Element Drive System Graphing-Modeling All the Shafts at One Time
    Mixing Different Alignment Measurement Methods
    Modeling Right-Angle Drive Systems
    Final Comments on Aligning Multiple-Element Drive Trains
    References
    ALIGNING V-BELT DRIVES
    Belt Drive Systems-Advantages and Disadvantages
    V-Belt Standards Information
    Sheave Information
    V-Belt Recommendations and Rules of Thumb
    Sheave and Belt Wear
    Adjusting Belt Tension
    Preliminary Alignment Checks for V-Belts and Sheaves
    Types of Sheave Misalignment Conditions
    Using a Straightedge to Measure Misalignment
    Measuring the Misalignment at the Sheaves
    V-Belt Machine Measurements
    Modeling V-Belt Alignment Problems
    V-Belt Alignment Modeling Sample Problem
    Laser Alignment Systems for V-Belts and Sheaves
    Bibliography
    BORE ALIGNMENT
    Aligning a Rotating Shaft with a Stationary Hollow Cylinder
    Aligning Two Hollow Cylinders
    Basic Measurement Principles and Nomenclature
    Cylinder Alignment Procedure
    Bucking in Process
    Correcting the Misalignment
    Laser Bore Alignment Systems
    PARALLEL ALIGNMENT
    Rough Alignment of Parallel Rolls
    Using Optical Alignment Equipment for Roll Parallelism
    Aligning the Rolls in the Vertical (Up/Down) Direction
    Aligning the Rolls in the Lateral (Side to Side) Direction
    Using Laser-Detector Systems to Measure Parallelism
    Using Roll, Pitch, and Yaw Positions of Rolls to Measure Parallelism
    Aligning Rolls and Their Drives-Sample Problem
    ALIGNMENT CONSIDERATIONS FOR SPECIFIC TYPES OF MACHINERY
    Drivers
    Bibliography
    THE HISTORY OF MACHINERY ALIGNMENT
    APPENDICES
    Appendix A: Machinery Data Card
    Appendix B: Sample Preliminary Alignment Record Sheet
    Appendix C: Sample Installation and Shaft Alignment
    Appendix D: Torque Values (SAE Grade 2 Bolts).
    Appendix E: Torque Values (SAE Grade 5 Bolts)
    Appendix F: Torque Values (SAE Grade 8 Bolts)
    Appendix G: Shaft Alignment and Related U.S. Patents
    Appendix H: Shaft Alignment Training Questionnaire
    Appendix I: Shaft Alignment Services Questionnaire
    Appendix J: Alignment Internet Web Sites
    Appendix K: Single Plane Balancing
    INDEX

    Biography

    John Piotrowski