Monition Ltd

Align Shafts

Why Align Shafts?
Precision alignment of shafts is critical because misaligned machines result in vibrations and premature wear of bearings, seals and couplings. Machines with rotating shafts are designed to run under optimal conditions. Misalignment will lead to harmful forces, deteriorating the performance of rotating machinery.

How is misalignment recognised?

• Premature bearing, seal and coupling failure
• Excessive radial and axial vibrations
• High casing temperature at the bearings, or nearby them, or high oil temperature
• High coupling temperature
• Oil leakage at the bearing seals
• Loose or broken foundation bolts and/or coupling bolts
• Similar equipment has less vibrations or has longer operation lifetime

Benefits of precision alignment

• Reduced vibration levels
• Increased meantime between failures
• Reduced maintenance cost
• Reduced energy consumption
• Increased production quantity and quality

Misaligned machines contribute to huge costs in repair and production loss every year. By introducing preventive maintenance, including regular alignment control, you minimise the number of unplanned stops due to machine breakdowns.

The Fixturlaser XA Laser Shaft Alignment System is an Expert tool to enable engineering and Maintenance personnel to align shafts with precision and ease.

Align Shafts with the powerful capabilities of the Fixturlaser XA System:

• Shaft alignment of pumps, motors and reducers
• Cardan shaft alignment
• Machine train alignment
• Dynamic measurements / thermal growth measurements
• Measurement of base flatness

Monition is the UK distributor for Fixturlaser equipment for shaft alignment.

Align Shafts of Critical Machines - Dynamic Measurements
Fixturlaser OL2R - Offline to Online Running Application for express measurements of Dynamic Movements

If your process operates within large temperature differences or other conditions that affect the machines, you might have a need to measure the dynamic movements. This is indicated by a high level of vibrations, persisting even after having performed alignment in cold condition. After measuring the dynamic movements in cold as well as in hot condition, the calculations are made and the target values are obtained.

Fixturlaser OL2R (Off-line-to-Running) is the perfect tool for measuring movements due to e.g. Thermal Growth, Process Forces, Background Vibration Levels, etc. The Fixturlaser XA is the only system on the market that includes this application.

OL2R, an accessory for the Fixturlaser XA Shaft Alignment System, makes it possible to receive the exact compensation data required for a precise alignment by making it possible to measure in both hot and cold conditions.

Fixturlaser OL2R (off-line-to-running) fixtures combined with Fixturlaser XA alignment systems put a stop to guesswork in measurement and alignment. With OL2R, changes in machinery alignment are mirrored by changes in position of the OL2R brackets. By simply measuring and documenting the initial position of the brackets, the actual changes in the alignment can be measured as alignment positions change.

Dynamic Movements Consist of:

• Thermal growth
• Pipe strain
• Movements in foundations
• Surrounding machines and processes
• Air pressure, pressure in liquids, etc.
• Sun light, wind and other environmental factors
• Cooling systems (fans, oil cooling, etc.)

Measurements:

• Measurement of machine position in operating and cold condition
• Gives you the real compensation values in a fast, easy and precise way
• Calculates the correct offset and angularity values to be used during the shaft alignment

Features:

• Makes it possible to calculate exact and precise offset values for a specific machine

Benefits:

• Reduced vibration levels
• High availability
• Trouble free operation
• Faster installation
• Minimised downtime
• Reduced energy consumption
• Reduced maintenance cost
• Documentation of installations and reconstructions

Align Shafts: Industry Application - Alignment of Windmills
Alignment of wind mills machinery can involve some unique challenges. Windmills contain a machine train, consisting of a wind turbine, gearbox, and generator, with a total weight between 300 - 500 tons.

The machines are installed at the top of a 50 - 80m high turnable tower. Measurement challenges include long coupling spans along with base plate flexibility and sagging. Flexibility and sag of the structure can result in offsets of several millimetres which need to be compensated for during the alignment process.

Correct alignment is critical because misalignment results in large energy losses as well as disturbing vibration and noise. Therefore, there are demands for more precise alignment. Using the Fixturlaser XA System together with OL2R allows for the measurement and precise compensation for the dynamic movements involved. Even "rough alignment" is easy using the dual transmitter and detectors.

There are demands for more accurate alignment. Using the Fixturlaser XA System together with OL2R, you are able to compensate for the dynamic movements involved.

Measurements:

• Shaft alignment
• Measurement of dynamic movements
• Flatness measurement of tower segments during building

Advantages:

• Not sensitive to vibrations
• Can be used for measurement of compensation values in running condition
• Easy to learn and use
• Dual lasers - improves rough alignment

Benefits:

• Minimised vibrations
• Minimised noise
• Increased speed
• Increased uptime
• Trouble free operation
• Faster installation
• Minimised downtime
• Documentation of installations and reconstructions

Further Information regarding the Alignment of Shafts
Monition can provide assistance in all your Laser Alignment applications. For further information on The Alignment of Shafts, to request a brochure or arrange onsite alignment of plant machinery, please telephone Monition on 01909 722000. Alternatively you can email us at sales@monition.com or complete our enquiry form and one of our sales team will contact you to discuss your requirements.