SHAFT ALIGNMENT
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SHAFT ALIGNMENT PROCESS
ACQUIP offers a comprehensive laser shaft alignment that is proven to eliminate the most common cause of machine vibration.
Reduced energy consumption
Mechanical seal repairs
Pump repairs
Longer Machine Life
ACQUIP offers a comprehensive laser shaft alignment that is proven to eliminate the most common cause of machine vibration, making it the most effective method for coupling alignment. Proper coupling alignment increases mean time between failures, bearing and seal life, and decreases power loss.
Taking advantage of the most advanced and precise laser alignment equipment in the market, ACQUIP can quickly improve the running condition and dependability of your machines. Shaft alignment is one of the mission critical components for optimum performance.
Several companies are still applying old methods that increase the chance of error and take a long time in order to perform these procedures on large rotating machinery. However, using this type of equipment can set drawbacks during your downtime. For instance, a dial indicator alignment requires a mechanical set up and can contribute to inaccuracies due to any user interpritation and math calculations. Unlike conventional methods, the laser shaft alignment performed can provide faster, easier, and more accurate results. The laser beam does not sag and can constitute a precise and uniform reference on all sorts of procedures such as motor shaft, motor coupling and bearing alignment. Our standard shaft alignment methods have demonstrated to be reliable and deliver optimal implementation on all types of industrial machines.
…Once you employ this process into all shaft alignments, the average time spent on shaft alignment will go down and the quality of the laser shaft alignment will go up.
Performing a correct shaft alignment procedure saves time and money. Misalignment is the most common cause of machine vibration. Understanding and practicing the fundamentals of shaft alignment is the first step in reducing unnecessary vibration, reducing maintenance costs, and increasing machine uptime.
Every shaft alignment should be performed from start to finish using the same fundamental process. Once you employ this process into all shaft alignments, the average time spent on shaft alignment will go down and the quality of the laser shaft alignment will go up.
You can also rent one of our Rotalign Systems to perform Laser Shaft Alignment, please fill out our Rental Request form, or contact us at +1 305 538 7101 / info@acquip.com
What Is Shaft Alignment?
Shaft Alignment is the process of positioning the rotational centerlines of two or more coupled shafts so they are collinear under defined operating conditions. In rotating machinery, proper shaft alignment ensures that torque is transmitted between the driver and driven equipment without introducing excessive mechanical loads into bearings, couplings, seals, or shafts.
From an engineering perspective, shaft alignment is not a static condition achieved only at rest. Accurate alignment requires consideration of machine geometry, mounting conditions, coupling design, shaft flexibility, and operational influences such as thermal growth and load variation. The goal is to minimize reaction forces and bending moments throughout the operating speed range of the machine.
Shaft alignment is a foundational practice in the installation, commissioning, and ongoing maintenance of rotating equipment including motors, pumps, compressors, turbines, gearboxes, and generators.
Why Shaft Alignment Is Critical for Rotating Equipment
Improper shaft alignment introduces cyclic and non-linear forces into rotating machinery, directly affecting reliability and performance. Even small deviations from acceptable alignment tolerances can result in disproportionately high mechanical stress.
From a failure mechanism standpoint, poor shaft alignment contributes to:
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Increased bearing loads leading to premature fatigue and spalling
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Elevated vibration levels, often presenting at 1× and 2× running speed
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Accelerated seal wear and leakage due to shaft deflection and orbital motion
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Coupling degradation, including elastomer breakdown or metallic fatigue
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Higher energy consumption caused by increased friction and inefficiency
In critical and high-speed applications, misalignment can also induce shaft bending stresses that propagate cracks and lead to catastrophic failures. For this reason, shaft alignment is a core element of precision maintenance, vibration analysis programs, and reliability-centered maintenance (RCM) strategies.
Common Types of Shaft Misalignment
Shaft misalignment generally manifests in three primary forms, often occurring simultaneously rather than in isolation.
Angular Misalignment
Angular misalignment occurs when the shaft centerlines intersect at an angle. This condition generates alternating bending forces that increase with speed and primarily affect couplings and bearings.
Parallel (Offset) Misalignment
Parallel misalignment exists when shaft centerlines remain parallel but are laterally displaced. This creates constant radial loading, increasing bearing reaction forces and seal wear.
Combined Misalignment
Most real-world machines exhibit a combination of angular and parallel misalignment. Combined misalignment produces complex vibration signatures and is one of the most common contributors to chronic reliability issues in rotating equipment.
In addition, axial misalignment or incorrect axial positioning can impose unintended thrust loads, particularly in machines with sleeve bearings or thrust-sensitive designs.
Engineering Consequences of Shaft Misalignment
From a mechanical engineering standpoint, misalignment alters load distribution within the machine. Bearings experience higher dynamic loads, lubrication films are disrupted, and seals operate outside their intended contact patterns. These effects compound over time, reducing component life and increasing maintenance frequency.
Misalignment-related failures are often misdiagnosed as lubrication issues or bearing defects, when the root cause is geometric error between coupled machines.
Shaft Alignment Tolerances in Real-World Applications
Shaft alignment tolerances are not universal; they depend on machine speed, coupling type, shaft length, and OEM recommendations. As a general rule, higher rotational speeds demand tighter alignment tolerances due to increased sensitivity to misalignment-induced forces.
Modern best practice relies on application-specific tolerances, often derived from ISO or ANSI guidance and refined through field experience. For critical equipment, alignment targets frequently include cold alignment offsets to compensate for thermal growth during operation.
Laser Shaft Alignment vs. Traditional Methods
Traditional shaft alignment methods, such as straightedges, feeler gauges, and dial indicators can provide basic alignment but are limited by setup accuracy, human error, and repeatability constraints.
Laser shaft alignment systems have become the industry standard for precision alignment due to their ability to:
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Measure angular and offset misalignment with high resolution
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Compensate for bracket sag and shaft rotation errors
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Provide real-time correction guidance during machine movement
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Document as-found and as-left alignment conditions
For modern rotating equipment maintenance, laser alignment is not merely a convenience, it is a necessity for achieving repeatable, verifiable alignment results within tight tolerances.
Working with ACQUIP on the job we had in Italy recently was the best experience I have had in this type situation. ACQUIP was very professional and the response time far exceeded my expectations. The rental equipment was in top shape and made it possible for us to take care of our customer in an emergency situation. We will look forward to doing business with you in the future. Thank you for your hard work.
ACQUIP’s engineers performed a great job for Siemens Energy . The Fluid Drive and Gearbox and Pump were all included in the task. Each component was aligned to “all” of Siemens procedures and specifications requested. The Siemens customer was very satisfied with the results of the alignment and process.
First I would like to thank you for your help. We need a piece of alignment equipment on site last minute do to a break down. ACQUIP responded to your request immediately, recommend the right tool for the job, and had the tool on site by 8:30 AM the following morning. Just outstanding customer service and support from the entire ACQUIP team.
ACQUIP was the best choice to rent the Laser Tracker. It speeded up the process! I will definitely come back on our next set of fixtures!
I highly recommend ACQUIP for executing both Tops on/Tops off and Tops off Steam path alignments.