INSTRUCTIONS FOR
INSTALLATION,OPERATION
AND MAINTENANCE
___________________________________________
Centrifugal pumps
Type HPX
CE-HPX-R-FLOW.DOC – rev. 0
Pump Division
Worthington S.r.l.
2
FOREWORD
FLOWSERVE products are the result of more than a century of progressive study and
development. Advanced design, proper selection of materials, and precision construction reflect
this wide experience. FLOWSERVE products will give trouble-free efficient operation with
minimum maintenance and repair.
This instruction book will familiarize management and operating personnel with pertinent details
and proper procedures for the installation, operation and maintenance of one of these products.
Designate below your identification of the equipment for which this book applies.
Unit Size
Identification No.
STUDY THIS INSTRUCTION BOOK
The descriptions and instructions included in this book cover the standard design of the equipment
and any common deviations when possible. This book does not cover all design details and
variations nor does it provide for every possible contingency which may be encountered. When
information can not be found in this book, contact the nearest FLOWSERVE Service Centre.
WARNING
Do not operate this equipment in excess of its rated capacity, speed, pressure and
temperature, nor otherwise than in accordance with the instructions contained in this
Manual.
This equipment has been shop tested and found satisfactory for the conditions for which it
was sold, but its operation in excess of these conditions will subject it to stresses and
strains which it was not designed to withstand.
Failure to heed this warning may result in an accident causing personal injury.
3
TABLE OF CONTENTS
I INTRODUCTION 5
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1.20
1.21
1.22
1.23
1.24
1.25
1.26
1.27
1.28
Safety
Installation, Operation and Maintenance Safety Procedures
Installation Safety Procedures
Operation Safety Procedures
Maintenance Safety Procedures
Construction
Parts description
Casing
Impeller
Casing cover
Shaft
Bearing housing
Bearings
Inducer
Coupling/Coupling guards
Baseplate
Check upon arrival
Care during storage
Long term storage
Inspection upon arrival
Storage
Inspection and maintenance
Painting and preservation
Associated equipment
Lifting equipment
To lift unit
To lift driver
To lift complete pump only
II INSTALLATION 15
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
Location
Foundation
Level the baseplate
Method of levelling baseplate using wedges or shims
Grouting
Shaft/Coupling alignment
Types of misalignment
Alignment using the Reverse Alignment method
Alignment using a graph (Reverse Alignment)
Assemble Coupling
Dowel Pump and Driver
Hot Alignment Check
Installation Check List
Piping
- Suction and Discharge Piping
- Bypass Line
Suction Strainer
4
III OPERATION 32
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
3.21
Technical Data
Effects of Specific Gravity
Effect of Viscosity
Changing the Pump Speed
Net Positive Suction Head (NPSH)
Minimum Continuous Stable Flow
Minimum Flow Control
Control Notes
Thermal Control
Pressure and/or Flow Control
Continuous Bypass Control
Operating Precautions
Pre-Operational Checks
Initial Start Up Procedure
Operating Checks
Normal Start Up
Securing the Pump
General Maintenance
Routine Maintenance
Trouble Shooting
Trouble Shooting Chart
IV LUBRICATION 43
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
Preparing Bearing Housing
Inspection
Replenishment
Oil Change
Lubrication Specification
Trico Oiler Setting
Bearing Housing Oil Fill Capacities
Bearing Housing Oil Limitations
V MECHANICAL SEALS 47
5.1
5.2
Description
Servicing Mechanical Seal
VI MAINTENANCE, DISMANTLING 48
6.1
6.2
6.3
Dismantling – General
Pump Disassembly Instructions
Disassembly of Pull Out Element
VII INSPECTION AND RENEWAL OF PARTS 53
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
General
Wear Rings (Impeller)
Case Wear Ring (and Casing Cover Wear Ring when Fitted)
Mechanical Seal
Throat Bush (If Fitted)
Bearing Handling Information
Bearing handling
Bearing Installation
Bearing Removal
Bearing Cleaning
Assembly
Torque Value Supplement
5
SECTION I
INTRODUCTION
This manual contains instructions for installation, operation and maintenance for your
FLOWSERVE Centrifugal Pump. The instructions are written for the use of personnel with a
general training in the operation and maintenance of Centrifugal Pumps.
Your pump has been designed to provide safe and reliable service. However, it is both a pressure
vessel and a piece of rotating machinery so that operators must exercise good judgement and
observe correct safety practices to avoid damage to the equipment and surroundings and to
prevent personal injury.
The pump has been designed for the duty specified in the customers order. F.P.D should be
consulted prior to any significant change of duty.
1.1 Safety
It is assumed that your safety department has established a safety programme based upon a
thorough analysis of industrial hazards. Before installing and operating or performing maintenance
on the pump and associated components in this manual, it is suggested that the safety
programme be reviewed to ensure that it covers the hazards arising from high speed rotating
machinery.
It is also important that due consideration be given to those hazards which arise from the presence
of electrical power, hot oil, high pressure and temperature liquids, toxic liquids and gases,
flammable liquid and gases. Correct installation and care of protective guards, shut down devices
and over pressure protection equipment should also be considered an essential part of any safety
programme.
Also essential are special precautionary measures to prevent the possibility of applying power to
the equipment at any time when maintenance work is in progress. The prevention of rotation due
to reverse flow should not be overlooked.
In general, all personnel should be guided by all the basic rules of safety associated with the
equipment and the process.
1.2 Installation, Operation and Maintenance Safety Procedures
In the following safety procedures you will encounter the words WARNING, CAUTION and NOTE.
These are intended to emphasize certain areas in the interest of personal and satisfactory pump
operation and maintenance. The definitions are as follows:
WARNING: An operating procedure, practice, etc, which if not correctly followed, could result in
personal injury, or loss of life.
CAUTION: An operating procedure, practice, etc, which, if not correctly observed, could result
in damage to, or destruction of equipment.
NOTE: An operating procedure, etc, which is essential to highlight.
These safety procedures are to be used in conjunction with the installation, operation and
maintenance instructions contained in the pump manual.
6
1.3 Installation Safety Procedures
1. Lifting equipment
Make sure that any equipment used to lift pump or any of its components is capable of supporting
the weights encountered. Make sure that all parts are correctly rigged before attempting to lift.
2. Coupling alignment CAUTION
Coupling alignment must be correct for successful operation. Flexible couplings will not
compensate for any appreciable misalignment, and rapid wear, noise, vibration and actual
damage to the equipment may be caused by misalignment. Therefore, the coupling must be
aligned within the limits given.
3. Driver rotation WARNING
The driver rotation must be checked before making up coupling. Actual damage to the
equipment and personal injury could result from operating the unit with incorrect rotation.
4. Suction and discharge piping
Provisio
n must be made to support suction and discharge piping to the pump to prevent excessive
nozzle loads and maintain pump to driver alignment.
1.4 Operation Safety Procedures
1. Operating conditions WARNING
In the interest of operator safety the unit must not be operated above the nameplate
conditions. such operation could result in unit failure causing injury to operating
personnel. Consult instruction book for correct operation and maintenance of the pump
and its supporting components.
2. Pumps handling heavy viscous liquids CAUTION
When pump is handling heavy viscous liquid, the temperature of the liquid must allow it to
be pumped easily. Liquid may have to be heated prior to pump start-up.
7
3. Pump priming CAUTION
Before starting or while operating the pump, the casing and suction line must be
completely filled with the liquid being pumped. The rotating parts depend on this liquid for
lubrication and the pump may seize if operated without liquid.
4. Pump by pass line CAUTION
When operating for some time at reduced capacity, much of the pump horsepower will go
into the liquid in the form of heat. A by pass must be provided under these conditions to
prevent the liquid in the pump from becoming hot enough to vaporize.
5. Operation at reduced capacity CAUTION
Damage to pump may result from prolonged operations at capacities less than 25% of the
best efficiency point
6. Bearing lubrication WARNING
Operation of the unit without correct lubrication can result in overheating of the bearings,
Bearing failures, pump seizures and actual breakup of the equipment, exposing operating
personnel to injury.
7. Operation inspections WARNING
Do not attempt any maintenance, inspection, repair or cleaning in the vicinity of rotating
equipment. Such action could result in injury to operating personnel.
8. Coupling guards WARNING
The unit must not be operated unless coupling guard is in place. Failure to observe this
warning could result in injury to operating personnel.
1.5 Maintenance safety procedures
1. Tagging for inspection or repair WARNING
Before attempting any inspection or repair on the pump the driver controls must be in the
"off" position, locked and tagged to prevent injury to personnel performing service to the
pump.
8
2. Isolating the pump WARNING
Before attempting to disassemble the pump, the pump must be isolated from the system,
by closing suction and discharge system valves, drained of liquid and cooled, if pump is
handling hot liquid.
3. Draining pump handling hot liquids WARNING
When pump is handling "hot" liquid extreme care must be taken to ensure safety of
personnel when attempting to drain pump. Hot pumps must be allowed to cool before
draining.
4. Draining pump handling caustic liquid WARNING
When pump is handling "caustic" liquid extreme care must be taken to ensure safety of
personnel when attempting to drain the pump. Protective devices of suitable protective
materials must be worn when draining the pump.
It should be understood that the information contained in this manual does not relieve
operating and maintenance personnel of the responsibility of exercising normal good
judgement in operation and care of the pump and its components.
5. Pumps on vacuum service WARNING
Before attempting any maintenance work on pumps in vacuum service, the pumps must be
isolated from suction and discharge system then carefully vented to return pressure in
pump casing to atmospheric pressure.
6. Oil ring inspection (where applicable) CAUTION
Remove the pipe plug(s) from the top of the bearing housing(s) and check to see that oil
rings are riding free on the pump shaft and are not hung up. Failure to observe this caution
could result in damage to or destruction of equipment.
9
1.6 Construction
1.7 Parts description
The type 'HPX' are horizontally mounted, vertically split, back pull out single stage, single suction
overhung process pumps, constructed to the requirements of API 610 specifications, for
continuous duty service in all process industries and industrial application within the pressure and
temperature limitations.
1.8 Casing
The casing is centre line supported with end suction and top discharge. It provides for the
immediate containment of liquid being pumped as the liquid is directed from the suction nozzle
through the impeller and then through the volute to the discharge nozzle. The casing also provides
the centre line attachment to the baseplate or support. A wear ring is mounted in the casing to
provide a close running clearance with the impeller wear ring.
1.9 Impeller
The impeller is a single suction, radial flow, closed design. The impeller is dynamically balanced,
keyed to the shaft and secured by locknut and lockscrew. Renewable wear rings are a press fit
onto the impeller hub and positively secured with radial screws.
1.10 Casing cover
The casing cover is designed to accommodate single, tandem or double elastomer and metal
bellow cartridge seals to the dimensional requirements of API 682. On certain models a wear ring
may be mounted in the cover to provide a close running clearance with the impeller back wear
ring.
1.11 Shaft
A high strength shaft is of stiff shaft design, machined over its entire length to close tolerances.
The shaft transmits the required power without vibration.
1.12 Bearing housing
The bearing housing is air cooled with fan type flingers provided at inboard and outboard ends.
The bearing housing contains the thrust and radial bearings and, for other than pure mist type
lubrication, serves as the oil reservoir for the bearing lubricating oil. For other than pure mist
applications, a constant level oiler is provided for maintaining required oil level. Labyrinth type
flingers help to seal the bearing housing to prevent contamination of the lubricating oil.
A finned type cooling insert is available as an option for the cooling of the lubricating oil. Provision
for purge oil mist is standard whilst pure oil mist lubrication is optional.
10
1.13 Bearings
Heavy duty, single row radial bearing and duplex angular contact thrust bearings arranged back to
back ensure long life under the most severe operating conditions. The bearings are a sliding fit in
the bearing housing and a light interference fit on the shaft in accordance with AFBMA
recommendations.
Lubrication of the bearings is provided by oil rings, thrower, purge mist or pure mist as a customer
option.
1.14 Inducer
Inducers are available on most pump models for low NPSH conditions. The inducer replaces the
standard impeller locknut and lockscrew. It is secured by proper cap nut and security washer.
1.15 Coupling/Coupling guards
Flexible spacer couplings are provided in various makes and models to suit customer preference.
(Fabricated heavy gauge sheet metal, or aluminium hinged or non- hinged guards are provided)
1.16 Baseplate
Standard baseplates are welded steel, drain pan type in conformance with API 610 standardized
dimensions, forces and moments. Horizontal driver alignment screws and vertical baseplate
levelling screws are provided as an option.
Special baseplates can be supplied to suit individual installation circumstances.
1.17 Check upon arrival
Your pump was carefully checked at the factory prior to shipment to assure its meeting the
requirements of your order.
It is suggested that the pump be inspected upon arrival and that any irregularities arising due to
shipping be reported immediately to the carrier and FLOWSERVE
1.18 Care During Storage
If the equipment is not to be installed immediately it should be stored in a clean, dry, vibration free
area and covered. Add "disessicant" between the covering and the pump.
Replace nozzle covers. Turn rotor in direction of rotation once a week.
Secure coverings after each check.
Electric Motors (Pump Driver) should not be stored in damp places without special protection
(Refer to Motor manufacturers instructions).
11
1.19 Long term storage
General
During extended periods of storage prior to installation, precautions must be taken to protect the
pump from deterioration. The various parts of the pump are protected prior to shipment by
applying varying grades of preservative to the parts. However, during shipment and handling the
preservatives are subjected to conditions that can cause their removal. Also, during extended
periods of time the preservatives may deteriorate. The listed procedures should be followed to
prevent deterioration of the pump during the extended storage period. These procedures may also
be supplemented by the experience of the person(s) performing the tasks.
1.20 Inspection upon arrival
When the pump is received it should be inspected for damage or other signs of rough handling. If
any damage is found it should be reported to the carrier immediately.
Inspect the preservative coating on various parts. If necessary, renew preservative in areas where
it has been rubbed or scraped.
Inspect all painted surfaces. If necessary, touch up the areas where paint has been chipped or
scraped.
Inspect all covers over pump openings and piping connections. If covers or seals for the covers
are damaged or loose, they are to be removed, and a visual inspection made of the accessible
interior areas for accumulation of foreign materials or water. If necessary, clean and preserve the
interior parts as noted above to restore the parts to the "as shipped" condition. Install or replace
covers and fasten securely.
1.21 Storage
If at all possible, the pump and its component parts should be stored indoors where they will be
protected from the elements. In no case should any pump element be subjected to extended
periods of submergence or wetting prior to start up. If it is not possible to store the pump and its
components indoors, precautions must be taken to protect them from the elements. Regardless of
whether storage is indoors or outside, the storage area should be vibration free. All boxes marked
for indoor storage should be stored indoors. When stored outdoors the pump and its components
should be protected from dirt, dust, rain, snow, or other unfavourable conditions by heavy plastic
sheets, canvas, waterproof burlap or other suitable coverings.
All equipment must be placed upon skids or blocks to prevent contact with the ground and surface
contaminants. Equipment must be adequately supported to prevent distortion and bending.
The pump shaft should be rotated, in the direction of rotation, at least 11/4 turns each week during
the storage period and any other periods of stand by.
When selecting a storage area the following should be taken into
consideration.
1. The deterioration of the equipment will be proportionate to the class of storage provided.
2. The expenses involved in restoring the equipment at time of installation will be proportionate
to the class of storage provided.
12
1.22 Inspection and maintenance
The stored equipment is to be placed on a periodic inspection schedule by the purchaser.
The responsibility for setting up an inspection schedule rests with the purchaser and will be
dependent upon the class of storage provided. It would be expected initially, inspection would
occur weekly, then depending upon the inspection reports being favourable or unfavourable,
inspection would continue weekly, monthly, or quarterly, as may be determined.
Each inspection should consist of a general surface inspection to assure that:
1. Pump supports are firmly in place.
2. Pump covers over openings are firmly in place.
3. Pump coverings, plastic or tarps are firmly in place. Any holes or tears must be repaired to
prevent entrance of dirt or water.
4. Pump covers are periodically removed from openings and interior accessible areas
inspected. If surface rusting has occurred, clean or coat with preservative.
5. If rusting occurs on exterior surfaces clean and repaint or coat with preservative.
6. Check individually wrapped parts for signs of deterioration. If necessary, renew preservative
and wrapping.
Six months prior to the scheduled installation date, an FLOWSERVE representative is to be
employed to conduct an inspection. This inspection may include, not necessarily in its entirety and
not limited to the following:
1. An inspection of all periodic inspection records as kept on file by the purchaser, and all
inspection reports that have been compiled during the storage period.
2. An inspection of the storage area to determine the "as stored" condition of the equipment
prior to any protection covers being removed.
3. An inspection of the equipment with protective covers and flange covers removed.
4. Depending upon the length of time the equipment was stored, the type of storage provided
(i.e. Indoor: heated, unheated, ground floor, concrete floor. Outdoors: under roof, no roof,
waterproof coverings, on concrete, on ground) and as a result of the inspection of 1,2 & 3
above the FLOWSERVE representative may require a partial or complete dismantling of the
equipment.
5. Dismantling may necessitate restoration of painted or preserved surfaces, and, or
replacement of gaskets, "O" rings, packing and bearings.
6. All costs involved during inspection, dismantling, restoration, replacement of parts and
reassembly will be to the account of the purchaser. All necessary labour, tools and cranes
will be supplied by the purchaser.
13
Upon completion of the inspection the FLOWSERVE representative shall submit a report to the
purchaser, and to the Manager of Customer Service, stating in detail the results of the inspection.
One month prior to installation of the equipment, an FLOWSERVE representative is to be
employed to conduct a final inspection. This inspection will be made to assure that the
requirements of the six months inspection report were satisfactorily completed and that the
equipment is ready for installation.
Upon completion of this inspection the FLOWSERVE representative shall submit a final report to
the purchaser, and to the Manager of Customer Service, advising the results of the final
inspection.
All costs involved in conducting the final inspection will be to the account of the purchaser.
Prior to and during start up, any requirements for the services of an FLOWSERVE representative
will revert back to the original contract agreement for equipment purchased, with revised costing.
1.23 Painting and preservation
Paints and preservatives used are either FLOWSERVE standard or 'special' as required by the
contract specification. Refer to your branch office through which the order was placed, or
FLOWSERVE for the description of paints and preservatives used on this order.
1.24 Associated equipment
Motors, Turbines, Gears, etc., being supplied by FLOWSERVE.
Generally rotors of associated equipment should be blocked to relieve bearing loads. Storage
should be indoors and dry. See the specific manufacturers storage requirements.
1.25 Lifting equipment
WARNING
Make sure that any equipment used to lift the pump or any of its components is capable of
supporting the weights encountered. Make sure that all parts are correctly rigged before
attempting to lift.
1.26 To Lift unit
Pump, driver and baseplate can be lifted as a unit. Sling from all four (4) eye bolts provided on
baseplate side rails. Failure to use all four (4) could result in permanent distortion of the baseplate.
Use as long a sling as possible, or use a spreader arrangement.
WARNING
Coupling bolting and spacer piece must be removed from between pump and driver half
couplings before lifting baseplate with pumping element.
To lift pump and baseplate, less driver, or baseplate alone, sling from all four (4) eye bolts.
14
WARNING
Do not lift pump, motor, baseplate unit by slinging from pump casing and/or eye bolt on
motor.
1.27 To lift driver
Refer to Manufacturers Instructions.
1.28 To lift complete pump only
Rig lifting straps at coupling end of bearing housing and at stuffing box extension. Make sure
straps are adjusted to obtain an even lift.
15
SECTION II
INSTALLATION
2.1 Location
Install the unit close to the source of the liquid to be pumped.
It is desired to have a straight length of suction pipe (approx. 8 to 10 times the pipe diameter) just
upstream of suction nozzle (No double turns).
When selecting the location, be sure to allow adequate space for operation as well as for
maintenance operations involving dismantling and inspections of parts.
Head room is an important consideration as an overhead lift of some type is required.
2.2 Foundation
The foundation should be sufficiently rigid and substantial to prevent any pump vibration and to
permanently support the baseplate at all points.
The most satisfactory foundations are made of reinforced concrete. These should be poured well
in advance of the installation to allow sufficient time for drying and curing.
The General Arrangement Drawing (In the last section of this manual) will furnish anchor bolt
locations, size of bolts, etc. See Figure 1 below.
GROUTING UNDER BASEPLATE
MAKE THIS DISTANCE
EQUAL TO LUG ON BASEPLATE
TEMPLATE FOR HANGING FOUNDATION BOLTS
BOLT
PIPE
WASHER
ALLOW BOLTS TO PROJECT FOR
Figure 1
Figure 2 below illustrates a recommended foundation bolt arrangement which can be used in lieu
of standard foundation bolts. Notice the large washer with lugs at the bottom. It should be welded
to the bolt and pipe sleeve to prevent turning.
Allow a little more than the specified threaded bolt length above the rail of the baseplate. The
excess can always be cut off if it is not needed.
A rough finish top surface is best when applying grout.
16
ALLOW AMPLE THREADED
BOLT LENGTH ABOVE
ROUGH CONCRETE
STUFF WASTE AROUND
BOLT WHILE POURING
CONCRETE
PIPE SLEEVE TO BE
THREE TIMES DIAMETER
OF ANCHOR BOLT
ROUGH FINISH
FOR GROUT
WELD A LARGE WASHER
WITH LUGS TO THE
BOTTOM OF BOLT
AND PIPE SLEEVE TO
PREVENT TURNING
Fig. 2 Arrangement of foundation bolt in foundation
2.3 Level the baseplate
Before putting the unit on the foundation, thoroughly clean the top of the foundation. Break off any
loose pieces of cement and roughen the top with a chisel to afford a good hold for grout.
NOTE
Coupling bolting and spacer piece must be removed from between the pump and driver half
couplings before lifting baseplate with pumping element
NOTE
When lifting baseplate with pumping element, sling baseplate from all lifting eyes provided.
Refer to Section 1.26.
Prepare sufficient steel plates to be placed below each baseplate jacking screw furnished with the
baseplate. The purpose of the plate is to spread the load of the screw without crushing the
concrete below.
17
Figure 3
2.4 Method of levelling baseplate using wedges or shims
Level the baseplate by using a machinist's level on the machined surfaces of the pump and driver
pads. Levelling is best achieved by adjusting the shim pack thickness under each holding bolt.
Carefully raise the baseplate by using either the baseplate jacking screws provided or by levering
with a suitable pinch bar or by installing a low level hydraulic jack.
Adjust the shim pack thickness and lower the baseplate.
Repeat this procedure in a logical manner at each bolt position until the baseplate is both straight
and level. A degree of 0.0035 inch per foot (.25mm per metre) length is achievable on most units
with a maximum of 0.005 inch per foot. (.40mm per metre length).
When the baseplate is level, pull down the foundation bolts so they are snug. This may have
disturbed the baseplate, so re-check the levels.
Ensure that shaft alignment per Section 2.6 can be achieved prior to grouting the baseplate.
18
2.5 Grouting
Build a dam around the foundation as shown in Figure 4 after levelling the baseplate. It is a matter
of personal preference whether the levelling wedges under the baseplate should be removed after
grouting. If you do not want to remove the wedges, carefully mark their locations before pouring
grout.
CAUTION
Before grouting, level machined pads of baseplate in both directions and perform a rough
shaft/coupling alignment. Alignment after grout has set will not be possible if above is not
satisfactorily completed.
GROUTING 1 TO 2
INCHES DEEP
CONCRETE
LEAVE TOP OF
FOUNDATION ROUGH
DO NOT FINISH
WITH TROWEL
FINISHED GROUT
DAM
Figure 4
Use a good, high strength, non shrink grout mix and install as per manufacturer's instructions.
Holes are provided in the baseplate to permit pouring the grout and stirring while acting as air
vents. Fill under the baseplate completely, stirring to assure correct distribution of the grout. Check
to see that the grout flows under the edges of the baseplate evenly.
NOTE
Do not vibrate baseplate when grouting, making sure baseplate is vented correctly and all areas
are thoroughly puddled to prevent any reasonant problems.
When the grout is thoroughly hardened, remove the dam and wedges, if desired, filling in the
holes they leave with grout.
NOTE
Pour grout until level reaches top of dam. Allow to dry sufficiently to prevent grout from overflowing
while completing the remaining grouting.
19
2.6 Shaft/Coupling alignment
CAUTION
Shaft alignment must be correct for successful operation. Rapid wear, noise, vibration and
actual damage to the equipment may be caused by shaft misalignment. The shafts must be
aligned within the limits given within this section.
NOTE
Adjustment to correct the alignment in one direction may alter the alignment in another direction.
Always check in all directions after making any adjustment.
Coupled equipment must be aligned to minimize unnecessary stresses in shafts, bearings and
coupling. Flexible couplings will not compensate for appreciable misalignment. Foundation settling,
thermal expansion or nozzle loads resulting in baseplate/foundation deflection and vibration during
operation may require the full coupling misalignment capability.
2.7 Types of misalignment
There are two types of shaft misalignment: angular and offset. Therefore, two sets of
measurements and corrections are required. Both types of misalignment can occur in horizontal
and vertical planes and are present in most applications.
A. Angular misalignment
In angular misalignment, the centre line of the shafts intersect, but are not on the same axis.
ANGULAR MISALIGNMENT
20
B. Offset misalignment
OFFSET MISALIGNMENT
COMBINATION OFFSET
AND
ANGULAR MISALIGNMENT
In offset misalignment, the shaft centre lines are parallel but do not intersect.
2.8 Alignment using the Reverse Alignment Method
The following practices are recommended when using the reverse method of alignment. These
should be carried out prior to main alignment.
CHECK FOR SOFT FOOT
This is a check to ensure that there is no undue
stress on the driver holding down bolts; owing
to non-level baseplate or twisting
To check, remove all shims and clean surfaces
and tighten down driver to the baseplate. Set a
dial indicator as shown in sketch and loosen off
the holding down bolt while noting any deflection
reading on the Dial Test Indicator - a maximum
of 0.05 mm (0.002”) is considered acceptable
but any more will have to be corrected by adding
shims, for example, if the Dial Test Indicator
shows the foot
lifting 0.15 mm (0.006") then this is the
thickness of shim to be placed under that foot.
Tighten down and repeat the same procedure
on all other feet until all are within tolerance.
NOTE
If the driver is an electric motor with sleeve bearings then the magnetic centre at which the rotor
will run must be set. This is usually done by lining up a groove in the shaft to a pointer fixed to the
motor body (refer to Motor Manufacture’s instructions).
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