Don't miss this opportunity to attend this time and field proven maintenance program. For over twenty years many industry facilities have reduced their maintenance cost by implementing this proven program into their maintenance system.
In a two-year study conducted by the USA and Canada in 1,000 industries it was determined that over 60% of failures were due to some form of misalignment. My 37 years experience places that number basically correct or even low. I have plants, where my PdM services are employed, that have greatly extended machine life by 3 & 5 fold while achieving planned scheduled maintenance and eliminating catastrophic failure and overtime. I have been teaching machinery alignment for over twenty years.
One Georgia paper company had me conduct 27 seminars for all their maintenance personnel due to the immediate notice by management in maintenance reduction and extended maintenance intervals. This seminar has been conducted for Boeing employees, Georgia Power, Kaolin Industries, Warner Robins AFB and other area consultants.
We cover all methods of alignment: Long Spacer Coupling, Indicator Reverse, Rim & Face and Lasers. We also cover: Piping and foundations. In addition, we discuss equipment peculiar to your industry with specifics on `how to correct' alignment for that application.
As a special get acquainted offer, I will provide my three-day seminar to 15 employees at a cost of $4,500.00. That's 25% off and includes materials and textbook. Normally cost $400.00 per student.
Mr. Jack Laster of Macon Tech has attended this seminar twice (478-757-3466). I also advise Macon Tech in the field of alignment, balancing, and vibration analyses. I also hold lectures there by invitation.
Table of Contents
Chapter 1 Value of alignment
Chapter 2 Safety
Chapter 3 Alignment Tools
Chapter 4 Misalignment Types
Chapter 5 Soft Foot and Bracket SAG
Chapter 6 Vibration and Alignment
Chapter 7 Machinery Bases, Leveling and Elevation
Chapter 8 Straightedge Alignment
Chapter 9 Couplings
Chapter 10 Alignment Method to Use
Chapter 11 Alignment Tolerances
Chapter 12 Performing Machinery Alignment
Chapter 13 Hot Alignment
Chapter 14 Vertical Alignment
Chapter 15 Plotting Indicator Reverse
Chapter 16 Plotting Rim & Face
FOREWORD
This book is a machinery alignment handbook for millwrights, maintenance mechanics and engineers. It provides orderly procedures incorporating fieldproventechniques. It supplies the reader with formulas, procedures for Indicator Reverse, Rim & Face, Vertical, and Long Spacer Coupling methods of alignment, plus computers and laser beam systems are discussed. Timely techniques are demonstrated. Hot alignment topics utilizing acculign, Dynalign, Laser and Optics are also discussed. Pitfalls associated with machinery alignment are covered from the effects of gravity and thrusting to applications of laser systems. This book is issued to those attending my alignment seminar or can be purchased separately. It is my intention in writing this book to impart or leave the reader with the ability to perform quality alignments.
My first alignment instructor, Mr. Clyde DeVault of Eastman Kodak. Both he and Mr. Lee King gave me inspiration because of their interest in quality alignment. That takes care of the sixty's.
There are also icons like Mr. Al Campbell, Mr. Jack Essinger, Mr. Ray Dodd and Mr. James Dreymala who have contributed to the advancement and recognition of this discipline.
Working with and around innovative men, craftsmen, engineers and even millwright helpers with an interest to know alignment and seek better methods -- It's these people with genuine concern that gave me the incentive to contribute to this discipline.
Also, there's great satisfaction in having the knowledge and ability to function in ones craft with the highest degree of accuracy and speed.
I've had as many as twenty-seven seminars for one company due to their recognizing the pay back in reduced maintenance and smoother operation immediately after employees had completed my training course.
I've also taught this seminar through Macon Technical Institute in Macon, Georgia. Mr. Jack Laster was my interface there. And, Mr. Laster also attended two of my seminars; one at Macon Tech and the other I gave at the Holiday Inn for several local area companies.
ABOUT THE AUTHOR
Sam Pickens has been actively involved in all types of alignment for over thirty years to include Indicator Reverse, Rim & Face, Long Spacer Coupling and Laser as well as various form of `hot' alignment. He has been in business as a consultant for over eighteen years. Prior to that he worked for a turbo machinery consulting firm specializing in alignment and vibration. Before that he was project engineer for ARAMCO in Saudi Arabia forming the predictive maintenance division for the Northern Area Maintenance.
My initiation and introduction into the craft was through Eastman Kodak's maintenance apprenticeship program. I left college to accept the apprentice program. After finishing, I went back to school though East Tennessee State University and the University of Tennessee achieving a mechanical engineering degree. He has been involved with alignment from hands-on to technical advisor; from designing hardware to writing software. His seminar has been taught to personnel in Water Plants, Waste Water Plants, Pulp, Paper, Power, Chemical, Petrochemical, and Petroleum Industries in the USA and abroad. His seminar is approved by the State of Georgia for certification of personnel in Water and Waste Water facilities and carries six continuing education hours of credit.
Who will benefit? Anyone involved with alignment - from hands-on millwrights to craft technicians. If you need to have knowledge of alignment to accept, certify, or assist; then this book is for you. The most proficient laser alignment technicians will benefit. It's about how to do alignment, not how to operate someone's computer. Some companies have conducted as many as twenty-seven seminars for all their maintenance staff, engineering and supervision.
A note of special thanks to the L.S. Starrett Company. The L.S. Starrett Company supplied photographs of their instruments and tools (see photos w/part numbers). Not only have they been a great help here but also to all of us who use their fine products in the work place since 1880.
For more information on their products visit their web site at http://www.starrett.com.
PROCEDURES and FACTORS AFFECTING
** SHAFT ALIGNMENT **
BACK TO BASICS
Over the past five decades there have been many different methods, opinions, and articles representing those opinions concerning shaft alignment. Each one's thinking believed to be the proper method; at least to that individual. After so much time has past, a solid agreement still hasn't been reached between all the related parties. Why? Some are in the business for different reasons: Oh, not that their attitude is wrong but sometimes the well meaning are not versed well enough in hands-on application. Example, not all programmers are good alignment technicians - nor are all alignment technicians good programmers . Sometimes we have a gap between alignment computers and the alignment technician. But, the ultimate responsibility lies with the alignment technician. The guy pulling the wrenches is the guy performing the alignment, not the computer or the computer program. I have found mistakes in several computer programs and even programs where the data are acquired directly and automatic calculations are made; such as laser alignment systems. A through understanding of alignment is a must for the technician - not necessarily just being able to understand the operation of the alignment computer or how to obtain readings from an instrument. Programs can mess up, instruments can fail; but, the technician can make an accurate calculation in five minutes or less. Or, at least, should be able to either do the math or make a plot.
The following presentation is based on over thirty years of experience . I have performed alignments (I think every kind), designed many different bracket configurations, and written several programs & papers concerning this subject.
Alignment used to be performed mostly with straight edges, feeler gauges, parallels, micrometers and sometimes a dial indicator. There were few who were doing alignment and fewer doing it correctly. In the 1960's or there about, more people were doing alignments and companies were demanding the use of dial indicators exclusively. Unfortunately, a lot of the alignment at that time got worse even though they were using dial indicators. The old timers using straight edges, feeler gauges, parallels and micrometers didn't have to cope with the effect of gravity in their calculations, and their end product was in most cases good and sometimes better.
In the early days of indicator alignment , the Rim & Face method was used almost exclusively without any consideration for gravity or axial float.
Without compensating for gravity and considering axial movement you've got two strikes against you. The third was soft foot - you're out. And some didn't consider that; ever see a broken casting of a motor's foot?
Another factor was training or the lack of it. The old millwright that knew alignment and had a reputation, guarded his knowledge. All too often as job security. That was unfortunate, but nonetheless all too often true.
This book is an endeavor to put proper procedures and methods in order and remove the difficulty that many mechanics, millwrights, and technicians have with shaft alignment. One major power company had bought laser alignment systems but their PdM manager noticed that alignment actually had gotten worse. He called me and asks, why? I explained several inherent flaws associated with some popular laser systems on the market today. He scheduled an alignment seminar. Once the technician is acquainted with proper procedures and techniques, then he only has to rely on his ability instead of some programmer that may have never aligned a machine.
Knowing several methods of alignment and the factors that affect those procedures, ultimately will produce results in untold savings, in production savings, time and money. The only prerequisite to the understanding of this material is a desire to understand alignment and the “want to” to do it right.
I can't over stress the importance of a quality maintenance program. Without grease the wheels won't turn. Lubrication ranks number one. Good maintenance practices are imperative. Alignment makes the wheels turn longer. Misalignment is the number one cause of machine failure. Misalignment may occur in the form of bearing bore to bearing bore (poor machining) eccentric condition, poorly machine couplings, substandard shafts or misaligned machines. Predictive maintenance (a good quality PdM program) will provide planned scheduled maintenance and machinery reliability. In addition, a PdM program with well-trained technicians will increase machinery life and eliminate reoccurring problems.
PdM Engineering