Blog

When moving machines for alignment,  always use jackscrews. If you don’t have them, beating on the machine frame with a steel-face hammer is a lousy idea.

First, you run the risk of damaging the bearings, seals, and other delicate components in your machines. Secondly, you have little control over the magnitude of your moves. Thirdly, it’s unprofessional. If you don’t have time to weld or screw-on jackscrew assemblies, consider using a couple of carpenter’s pipe clamps, tensed against each other. This makes for a handy portable jackscrew arrangement that is safe, inexpensive, and offers you plenty of control. If this is not possible either, and you must hit the machine with a hammer, then at least do so with a plastic-face, shot-loaded dead-blow hammer.

How to Analyze Unexpected Results After Performing a Shaft Alignment Horizontal Live Move

With over 14 years of experience in the complex industrial world, it has become evident that certain individual parts within pumps and motors stand out in reaping the benefits of precision alignment. Let’s start with pumps, an indispensable machine in various industrial processes for moving fluid through the plant and maintaining system pressures. Achieving precision alignment is instrumental in increasing the life of certain components within pumps, such as impellers, seals, bearings and shafts. Performing precision alignment not only minimizes wear and tear but optimizes efficiency, ultimately extending the overall lifespan of the machine and contributing to the reliability of the entire system.

Shifting our attention to motors, the unsung heroes driving the majority of industrial operations, the importance of precision alignment is highlighted when looking at certain motor components. Misalignment between two machines can have a crucial effect on elements such as motor windings, bearings and shafts, resulting in an increase in energy consumption, unwanted vibration, and premature failure. Prioritizing precision alignment after installation, and after repair or overhauls will prove beneficial, helping maintenance departments enhance motor efficiency, reduce maintenance costs, and fortify the overall reliability of the machinery.

In the world of rotating machinery, laser alignment systems are a key tool in the arsenal of maintenance toolrooms. Laser alignment systems offer unparalleled accuracy for detecting soft foot and pipe stress, surpassing the limitations of traditional methods. Laser alignment eliminates guesswork, providing precise measurements and adjustments to save components such as couplings, shafts, and bearings within most rotating machines, as well as impellers and seals within pumps. Using laser alignment technology not only ensures optimal performance but also minimizes the risk of breakdowns. In essence, the pursuit of precision alignment is not just a best practice; it is a strategic activity for everyone aiming to maximize productivity in the ever-evolving landscape of industrial machinery.

Watch our Shaft Alignment Know-How: The Basics video to learn the fundamentals of precision machinery alignment.

I use a Laser Alignment System, so I am Performing Precision Alignment, Right?

Aligning belt drives and pulleys is crucial for several reasons:

1. Efficiency: Precision belt pulley alignment ensures that power is transmitted smoothly from the belt to the pulley, maximizing the efficiency of the system. Misalignment can lead to energy losses and decreased overall performance. Such precision alignment is best achieved with tools such as the Easy-Laser XT190.
2. Component Longevity: Correct alignment reduces bearing failures as well as wear and tear on belts, pulleys, and other related components. This extends their lifespan and minimizes the need for frequent replacements, reducing maintenance costs.
3. Reduced Vibration and Noise: Misalignment can cause vibration and noise in the system, leading to reduced power transmission efficiency as well as potential damage to machinery.
4. Energy Savings: A well-aligned system requires less energy to operate. Misaligned belts and pulleys can result in increased friction, leading to higher energy consumption. Proper alignment contributes to energy efficiency, reducing operational costs.
5. Prevention of Overheating: Misalignment can generate excessive heat due to increased friction. This can lead to overheating of components, reducing their effectiveness and potentially causing damage. Proper alignment helps prevent these issues, ensuring optimal operating temperatures.
6. Improved Performance: Properly aligned belts and pulleys contribute to overall system reliability and performance. It reduces the likelihood of unexpected breakdowns and ensures consistent operation over time.
7. Enhanced Safety: Misaligned belts and pulleys may pose safety risks as they can lead to unexpected failures or accidents. Proper alignment reduces these risks, creating a safer working environment.
8. Cost Savings: The combination of increased efficiency, reduced maintenance needs, and lower power consumption translates into cost savings over the long term.

SUMMARY:

Aligning belt drives and pulleys is essential for maximizing efficiency, extending component life, reducing vibration and noise, saving energy, preventing overheating, improving overall performance, enhancing safety, and realizing significant cost savings.

Using a laser alignment tool with visual targets such as the Easy-Laser D92 or the DotLine Laser can achieve greater accuracy than aligning by means of a straightedge or string. However, aligning with lasers that have a digital readout will achieve true precision, and in the case of the Easy-Laser XT190 generate documentation to prove that the work was achieved to specified tolerances.

Download our Pulley Alignment Guide plus 5-Step Procedure for information on the implementation of good pulley alignment of belt-driven equipment including terminology, alignment methods, belt maintenance, storage and tensioning as well as a 5-Step Sheave/Pulley Alignment Procedure.

Uncover Hidden Savings and Opportunities in your Belt-Driven Machines

What is torque?

By definition, torque is a twisting force, but as it pertains to fasteners, it is the amount of twist we put into that fastener to achieve clamping force with that fastener. Proper torque is the twisting force required to accurately apply the desired clamping force, working within the limitations of the fastener and the materials to be fastened.

What is the reason behind proper torque?

What are we trying to hold together? Different materials call for different torque. Higher loads require higher torque. There is a design parameter that calls for the correct amount of clamping force. The expected performance of equipment is best met when specifications are maintained. Under-torqued conditions normally lead to mechanical looseness. An over-torqued condition can lead to distortion, fastener fatigue, parts fatigue, and structural failure or broken components.

How to store torque devices

Most technicians have been told throughout their career to store a torque wrench at a “0” load. This, in most cases, is incorrect. If the torque wrench is the spring-loaded type, with a rotating handle to set the spring tension, the tool manufacturer normally indicates a specific setting to properly store the device. If left at “0”, the spring is allowed to expand and contract with temperature changes, changes in humidity, or vibration from transport. By having some tension on the spring, those changes are reduced to a minimum effect on the tool’s ability to achieve accurate torque. Newer torque wrenches, like a digital one or the Pall-Pull wrenches, do not have this issue and can be left at the set point for the last use.

How to prepare for proper torque

1. What is the torque spec? Most equipment manufacturers will give specifications for fastener torque. If not, standard torque charts are available almost anywhere. Specifications are given for different thread diameter, thread pitch, and quality (or grade) of the fastener.
2. To lubricate or not? Adding any sort of lubrication to the fastener drastically changes the coefficient of friction required to apply that twisting force, which in turn changes the clamping force of the fastener. Most manuals will include a note as to what kind of lubrication is to be used if any.
3. Proper tooling: Having a tool capable of applying accurate torque is at the heart of the operation. Adding a longer handle to a smaller torque device is not a good way to maintain accuracy. Always work within the design limitations of the tools.
4. Proper techniques: Torque should always be applied in a smooth, repeatable manner. Jerking motions on the end of the handle yield much higher loads. Applying the old “double click” trick vastly changes the torque on the second click and should not be done. If you want to verify that something is properly torqued, let everything relax, and apply force smoothly. If the fastener does not turn anymore when the device indicates the desired torque, then it was properly torqued

What to inspect for proper torque

Over time, things can affect how the clamping force changes in a fastener. Heat, vibration, load cycles—all of these can reduce the ability of a joint to maintain a working condition. In some instances, regular checks are required, with intervals that open as the joint is constantly found to be properly torqued. The first time a joint is found to be loose, the interval goes back to short-term checks to prevent failure. Sometimes, the simplest indicators work the best. Cracked paint marks, bolt tabs, or even safety wire can give quick inspection points, and ensure that everyone did their part to #Keepitrunning.

Visit our Knowledge Center for resources and tools to help you succeed when implementing and using our maintenance technologies.

Precision Maintenance: The Torque Wrench. Check Out These 15 Helpful Tips!

Visiting more than 150 industrial sites has helped me realize that precision laser alignment tools have become a focal point in most companies’ maintenance strategies. One significant advantage of employing laser alignment tools is the unparalleled accuracy they offer in aligning rotating machinery. The precision achieved with these tools ensures that critical elements such as shafts and bearings are excellently aligned, reducing wear and tear. This, in turn, extends the lifespan of rotating assets, minimizing the frequency of breakdowns and subsequent downtime. The efficiency gained from precision laser alignment directly contributes to increased reliability and operational continuity, aligning seamlessly with our commitment to optimizing asset performance.

However, it’s crucial to acknowledge the investment and training required for implementing laser alignment tools. The initial cost of acquiring these advanced maintenance tools can be a deterrent for some industrial facilities. Moreover, ensuring that maintenance personnel are adequately trained to operate the laser alignment tool effectively is essential. This training incurs additional costs and may pose a challenge in terms of time and resources. Additionally, as with any technology, there is a learning curve associated with the adoption of laser alignment tools. It may take some time for the maintenance team to become fully proficient, potentially leading to a temporary decrease in efficiency during the initial stages of implementation. Choosing a company like LUDECA that provides resources such as the 5-Step Shaft Alignment Procedure below and providing short and long courses discussing alignment fundamentals, can help expedite that learning curve.

Despite the challenges, the long-term benefits of precision laser alignment tools outweigh the drawbacks. The increased accuracy and efficiency over older methods, reduced maintenance costs, and extended lifespan of rotating assets make the investment worthwhile. As we, in the industry, continue to prioritize the optimization of our processes, the adoption of laser alignment tools remains a strategic move towards achieving operational excellence and ensuring the sustained performance of our rotating machinery.

3 Benefits of Precision Shaft Alignment

Ensuring proper sheave alignment on multi-belt drives involves several good practices. When dealing with multiple belts and sheaves, a thorough inspection of each belt and its grooves for wear is crucial. In cases where any belts are slipping, it becomes imperative to replace all belts together.

Achieving precise alignment between pulleys can be accomplished through various methods. One approach involves using a machinist’s straightedge, while another entails placing a tightly drawn piece of string across the faces of the sheaves to verify if all four points of contact are made. Alternatively, employing a laser pulley alignment tool such as the Easy-Laser XT190 provides a more advanced and accurate alignment solution including the ability to generate an alignment report.

Regardless of the chosen alignment method, it is advisable to monitor changes in angularity and offset of the sheaves during the belt tensioning procedure. This monitoring should coincide with the tightening of hold-down bolts on the machine being adjusted, to ensure no unwanted or unexpected movement occurs during the tightening procedure. By doing so, the alignment can be maintained accurately, ensuring optimal performance and longevity of the multi-belt drive system.

Download our 5-Step Sheave Pulley Alignment Procedure for a simple and effective procedure for sheave pulley alignment of belt-driven equipment.

Now You Can Detect and Quantify Belt Driven Rotating Equipment Defects!

In our previous blog, we discussed the: Shaft Alignment Measurement Mode: Multi-Point Method. In this blog, we continue with the next method: Uncoupled Sweep. 

The Uncoupled Sweep Measurement mode allows you to measure uncoupled machines with ease. Start from any rotational position and take measurements by rotating the shaft with the S-laser in front of the shaft with the M-laser and vice versa, essentially passing one laser in front of the other, alternating. Uncoupled sweep is ideal for machines that are difficult to rotate or machines that cannot be rotated at all (in which case you slide the laser brackets around).*

Below are some examples of machines that are difficult or not possible to rotate:

• Gas turbines.
• Wind turbines.
• Gear boxes.
• Mine rock crushers.
• Ball mills.

This measure mode is available on the Easy-Laser XT770, XT660, and XT550 laser shaft alignment systems.

*Note that in these cases you will not actually be measuring centerlines of rotation, and the accuracy of your results will depend on shaft or hub, out of roundness and the care with which you reposition the measurement components each time.

Watch our Shaft Alignment Know-How: Repeatability to learn the importance of achieving repeatability of measurements before making alignment corrections.

Make Uncoupled Laser Shaft Alignment Easy with These Two Tools!

As part of our training program, we simulate various scenarios, to teach trainees how to see through a problem to a solution. To this end, the Soft Foot Analysis Form is a simple yet effective aid. Soft foot is machine frame distortion. It is evidenced by the movement of the machine shaft as the anchor bolts are tightened or loosened. How the shaft moves is subtle and depends upon the specific machine condition producing the casing distortion.

The Soft Foot Analysis form:

After reading all four feet with a laser shaft alignment system mounted on the machine shafts, the form asks you to feeler gauge the airgap at each corner of the feet that have been determined to be “soft”, with the other three feet tight. Miking the outer three corners of the foot is sufficient. Filling out the form allows you to visualize a “picture” of what is going on by comparing the shape of the airgaps to each other. This in turn leads to efficient diagnosis and correction of almost every kind of soft foot.

All the laser shaft alignment tools can do is detect if a soft foot condition exists since it is observing the reaction of the shaft as a foot is loosened. However, it cannot immediately tell you how to correct the problem.

The Soft Foot Analysis Form, when used in conjunction with our “Soft Foot Find-and-Fix Infographic”, helps you to determine which foot to shim and how much, or to determine if you have a ‘Bent’ foot condition.

The complete diagnostic procedure can be found in the LUDECA Shaft Alignment Training Manual, which every trainee receives as part of a LUDECA alignment training course. Please contact us for more information.

Watch our Shaft Alignment Know-How: Soft Foot to learn about the effects and importance of measuring and correcting Soft Foot when performing shaft alignment.

Make aligning your machinery easier, start by correcting Soft Foot

In our previous blog, we discussed the: Shaft Alignment Measurement Mode: Continuous Sweep Method. In this blog, we continue with the next method: Multi-Point. 

The Multi-Point measurement mode is among the most versatile measurement modes as it allows you to measure under any condition. It lets the user begin the measurement from any rotational position and take as many points as necessary to achieve excellent measurement quality every time. The points can be taken at any rotational position and can be as close together as 1 degree apart. A minimum of three measurement points is required, well distributed around the shafts to obtain accurate results. This measurement mode is designed for the Easy-Laser XT550, XT660, & XT770. Below are some examples:

• Easy-to-rotate machines

  • For machines that are easy to rotate, take a minimum of three points spaced approximately 120 degrees apart to cover a full rotation of the shafts evenly. However, taking more points is always better as it gives the system more data to work with.

• Difficult to rotate machines

  • For machines that are very difficult to rotate, the forces required to rotate the shafts may induce shaft deflection. Using Multi-Point we can relieve the rotational force and let the machine rest with each point taken, thereby avoiding shaft deflections completely.

• Uncoupled measurement

  • For uncoupled machines, trying to rotate both shafts together is next to impossible. Using Multi-Point, we can use the OLED display on top of each Laser/detector unit to align both the S and the M measurement units to the same angle. This will simulate the machines being coupled and allow us to get as many points as needed without any difficulties.

• High vibrations

  • For environments with high vibration from surrounding running machines or processes, using the Multi-Point measure mode lets us use the filter located at the bottom of the measuring screen to compensate for this environmental vibration. The higher the filter value the higher the vibration that can be compensated for. Since the shafts are allowed to rest at each measurement position as long as necessary to achieve stable readings, inaccuracies are eliminated.

• Limited rotation

  • For machines with obstructions to rotation or to line-of-sight for the lasers, the Multi-Point measurement mode allows you to accurately measure misalignment with as little as 40 degrees of shaft rotation. Take as many points as possible within the small arc of rotation available to you and you will still obtain reliable misalignment readings.

Watch our Shaft Alignment Know-How: Why Alignment to learn the benefits of precision machinery alignment.

Shaft Alignment with 4 Different Measurement Methods

When purchasing a laser shaft alignment system, consider the following things to ensure you choose the most suitable and effective solution for your specific needs:

1. Accuracy and Precision: Look for a laser shaft alignment system with high measurement accuracy and precision. The system should provide reliable and repeatable results for precise alignment adjustments.
2. Ease of Use: Choose a laser shaft alignment tool such as the Easy-Laser XT-series that is user-friendly and easy to operate. Intuitive interfaces, built-in help, and straightforward procedures like LUDECA’s 5-Step Shaft Alignment Procedure contribute to efficient and error-free alignment processes.
3. Versatility: Confirm that the alignment system is versatile and compatible with a diverse range of machinery types and sizes. A flexible system should adapt seamlessly to various measurement applications, including both horizontal and vertical installations. It should include checking for Soft Foot as well as compensating for thermal expansion of the machines (thermal growth).
4. Durability and Build Quality: Assess the durability and build quality of the laser alignment system. It should be designed to withstand the conditions of industrial environments—ideally rated for both IP66 and IP67 water-, shock- and dustproof.
5. Range and Reach: Consider the measurement range and reach of the system. Ensure it can cover the distances and dimensions relevant to your specific machinery and application requirements. Preferably, it should have a distance measurement range of at least sixty feet to easily handle applications such as cooling tower fans and deep submersible pumps.
6. Flexibility: Various applications may demand specific alignment measurement approaches. Having different measurement modes such as Continuous Sweep and Multipoint allows the system to adapt to the specific requirements of each application.
7. Alignment Tolerances: Make sure the alignment system has a built-in tolerance check. The best laser alignment systems have built-in ANSI/ASA tolerances and perform their tolerance evaluation based on the condition displayed at the coupling and compare it to the standards for the operational speed of that machine. Even better systems allow you to use any alignment tolerances of your choice.
8. Expandable: Choose an alignment tool that grows with your needs by offering the ability to add other measurement capabilities such as belt pulley alignment, vibration checks, straightness measurement, and flatness measurement.
9. Reporting and Documentation: Look for a laser alignment system that generates comprehensive PDF reports containing alignment results, complete with photos and notes, and with the ability to email the report directly from the alignment computer. This detailed documentation serves as a valuable resource for maintenance records, ISO compliance, and quality assurance purposes.
10. Training and Support: Check the availability of alignment training resources and support from the vendor. Adequate training ensures that users can make the most of the system’s capabilities, and reliable technical support is crucial for addressing any issues that may arise in the field.

By carefully considering these factors, you can make an informed decision when selecting a laser shaft alignment system that meets your specific requirements and contributes to efficient and reliable machinery alignment at your facility.

7 Reasons Why Machines Need Laser Shaft Alignment Technology

In our previous blog, we discussed the: Shaft Alignment Measurement Mode: EasyTurn™ Method. In this blog, we continue with the next method: Continuous Sweep. 

The Continuous Sweep Measurement mode allows you to begin an alignment measurement from any rotational position. Simply rotate the shaft and let the tool record the points as you go around. With the ease of use, the capability to take hundreds of points, and a minimum requirement of only 40° of rotation, this measurement mode is the fastest and most straightforward way to measure misalignment. Sweep comes standard on the Easy-Laser XT660 and Easy-Laser XT770 laser alignment systems and can be used to tackle almost any alignment you encounter.

When to use the Continuous Sweep measurement mode:

• When the shafts are coupled together.
• When the difficulty in rotating shafts is easy to medium.
• When it is difficult to stop rotation once initiated.
• When only a small arc can be measured.
  • Rotate slowly and collect as many points as possible.

Below are some tips on how to take excellent readings while using the Continuous Sweep measurement mode:

• Rotate the shafts smoothly.
• Always rotate in the same direction, preferably in the direction of rotation of operation.
• Try to make one continuous rotation.
• Slower rotation equals more points, and more points equals better results.
• Try to do a full revolution or 360 degrees of rotation if possible.
• Never take readings by rotating the shafts in different directions.

Watch our Shaft Alignment Know-How: Repeatability to learn the importance of achieving repeatability of measurements before making alignment corrections.

When Laser Aligning, Do You Zero at 12 o’ clock Position?

In our previous blog, we discussed the: Shaft Alignment Measurement Mode: 9-12-3 The Classic Three-Point Method. In this blog, we continue with the next method: EasyTurn™. 

The EasyTurn™ shaft alignment measurement mode allows you to begin the measurement from any location and take a total of three points. The points can be taken at any rotational position of the shafts and can be as close together as 20 degrees for a total rotation of only 40 degrees. This measurement mode is designed for the Easy-Laser XT440 laser shaft alignment tool and can be used to tackle almost any alignment you encounter. Below are some examples:

Easy to rotate machines:

• Take three points at approximately 120 degrees to cover a full rotation of the shaft evenly.

Difficult to rotate machines:

• Rotate as much as possible each time to take your three points. Keep in mind you need to turn at least 20 degrees before you take your next point.

Uncoupled alignments:

• Using the OLED display on top of each laser/detector unit, rotate both the S and the M measurement units individually to the same rotational position or angle. This will simulate the machines being coupled. This allows you to take the three points as if the machines were coupled.

High vibration:

• By using the filter located at the bottom of the measure screen we can compensate for environmental vibration. The higher the filter value the more filtration is applied. Select the lowest value where the readings stabilize.

Watch our 5-Step Shaft Alignment Procedure [Motion Graphic] which outlines an easy and effective way to align your rotating equipment and brings you one step closer to best practices for your alignment program.

That Dam Jackshaft Alignment was Easy!

Measurement points are recorded at three fixed clock positions: 9, 12, and 3 o’clock. This is the classic three-point method which can be used in most cases. Below are some applications where this mode is preferred:

• Vertically-oriented alignments:

  • When performing an alignment on a vertical machine the automatic inclinometer used to determine the shaft’s rotational angle no longer works, because it is gravity operated. Therefore, use the 9-12-3 method so that you can manually set the angles or in this case clock positions.

• Horizontal machines which are installed at an angle due to specific industry or plant requirements. See examples below:

  • Where the machine are at an angle axially and the sensor can’t determine true zero position. See Figure 1 below:

• • Where the machines are installed at a rotational angle and the sensor true zero position does not coincide with the actual zero position. See Figure 2 below:

Download our 5-Step Shaft Alignment Procedure for a simple and effective procedure for shaft alignment of rotating equipment!

Shaft Alignment with 4 Different Measurement Methods

Use ANSI Shaft Alignment Tolerances to help solve base-bound and bolt-bound situations. If a base- or bolt-bound situation presents itself during an alignment, take advantage of the outer limits of the tolerance envelope to help overcome the problem. It may be possible to optimally position the machine to meet the minimal ANSI tolerances and eliminate the bolt-bound situation altogether.

Say, for example, a machine is horizontally bolt-bound at the inboard feet. It is currently within precision angularity tolerance but is just shy of satisfying the offset tolerance. A possible solution for this is to try adjusting the offset by moving only the back feet and pivoting the machine about its front feet, thereby causing the offset to also fall within minimal tolerance, without compromising the angularity in the process. While this may cause the angularity to shift from precision to standard tolerance, this is perfectly acceptable so long as both the angularity and offset fall within ANSI Tolerances when you are finished. Some laser alignment systems even allow you to test the effect of proposed moves before you actually make them, thereby allowing you to determine if a proposed move such as the one described above will work before expending the time and effort actually trying it.

By evaluating the alignment situation objectively, and planning a move to remain within the tolerance limits of the alignment conditions, you can avoid unnecessary moves, machining, or hardware alterations to achieve the alignment. This will save you time and money!

Below are the ANSI tolerance tables for both short-flex and spacer shafts:

Watch our Shaft Alignment Know-How: Bolt-Bound video and learn about the options of achieving alignment when in a bolt-bound or base-bound condition!

Alignment Tolerances Carved in Stone. Details of new ANSI standard provide clarity for an important industry issue.

Within the industry, maintenance of machinery and plants is routine work. However, not everyone knows how to minimize future costs and risks for downtime from the start. Although it is so apparent!

Increased sustainability and reduced energy consumption

Everywhere in our society, machines are used for producing varying items, process materials, pump fluids, etc. These machines must be given the correct prerequisites to do the job for which they were designed. The importance of this increases with the naturally growing demands for sustainability and productivity that we face in our society. We are constantly reminded of the need for more energy-efficient solutions for the sake of our environment, right? This is where precision alignment with laser measurement systems comes in.

7 Reasons Why Machines Need Laser Shaft Alignment Technology

When the beverage industry started to market its products in aluminum cans, a new by-product for industrial maintenance was created— soda and beer cans were sometimes used as shimming material for electric motors. Aluminum cans were flattened out and a slot cut into them to allow the shim to fit under the foot of the motor and accommodate the hold-down bolt. Of course, they only came in one thickness and the flattened pieces were not very even. Unfortunately, we came across such crude contrivances quite often.

Accurate machine adjustment is an essential element in any alignment process and a good-quality shim is a must. So… how to select a good quality shim?

• Use only slotted Precut Stainless Steel Shims since they eliminate material waste, time-consuming hand-cutting and deburring, and for heavy gauge shims the need to torch cut and mill.
• Stainless Steel 304, Monel, or other full hard materials protect against rust and deformation.
• Stock different precut shim sizes (A, B, C & D) for the correct fit on all motors and generators in accordance with their frame size.
• Shims should be etched (not stamped or inked) with thickness and size to facilitate identification and re-use.
• Thirteen standard shim thicknesses allow all possible shim change combinations up to 150 mils thick with just 3 shims, so make sure you always have all thirteen thicknesses on hand; this will actually save you money and prevent a “squishy foot” soft foot from too many shims under a foot!
• Always mike all shims 50 mils and thicker. These, while flat and even in their thickness throughout, may not necessarily be of the exact thickness marked on the shim, since these thicker thicknesses are always nominal and not exact.

Download our precut SS shims price list.

The 5 Do’s and Don’ts of Shimming

In industrial facilities, the efficient operation of condensate pumps is crucial for maintaining production processes and avoiding costly downtime. Proper alignment is a crucial aspect in maintaining the performance of these pumps, with vertical alignment playing a critical role.

When aligning a vertical condensate pump, there are several key considerations to keep in mind. Here are a few:

• Shaft Alignment: The alignment of the pump and motor shafts is crucial for ensuring smooth operation and preventing excessive wear and tear on the components. Any misalignment can lead to increased vibration and potentially cause premature pump or motor failure.
• Base Plate Flatness: The base plate on which the pump is mounted must be level and flat to provide a stable foundation for the pump. A distorted or uneven base plate can cause misalignment and compromise the performance of the pump.
• Pump Shaft Bearings: Condensate pumps are typically assembled and bored in one operation to ensure bearing alignment. The pump components should be marked and pinned prior to bearing and pump shaft inspection to prevent misalignment during reassembling as the components may not be properly indexed to each other.
• Coupling Consideration: A condensate pump usually has a rigid type of coupling that supports the pump shaft. The coupling must be disengaged and the pump shaft should be centered to the bearing housing. The shaft alignment should then be checked between the static pump shaft and the rotatable motor shaft.  If the coupling is flexible (such as a gear-type coupling as shown below), the measurement can continue using alignment methods that involve rotating both shafts.

By considering these best practices, you can ensure the optimal performance and longevity of your vertical condensate pump. Regular maintenance and alignment checks can also help maintain performance and prevent costly downtime.

Laser Alignment for a Vertical Water Pump with Easy-Laser XT

It’s time to talk about torque! This topic is one of the most neglected aspects of Machine Maintenance. Equipment is designed to perform tasks reliably and efficiently. This can be accomplished if the machine is used as intended, and maintenance performed according to the specifications established by the manufacturer of the machine. There are always adjustments needed to accommodate local conditions, but those adjustments rarely mean making changes to specifications such as torque. If that specification is not adhered to, performance and reliability can suffer.

First, let us talk about what torque is. In a normal situation, the rotational force is applied to turning a fastener to achieve a specific clamping force. We are turning the nut or bolt until the resistance to that turning action reaches a certain point. After that point, we are stretching that joint into what is called the “elastic” working load range for that fastener. If this has been done correctly, the fastener should return to its pre-stretched length if the force is removed. In a case where that stretch does not go away, we have trespassed into the “plasticized” range for that fastener, and it can no longer create the clamping force needed for that joint. If you have ever felt a bolt have a lot of resistance to being turned, then all of a sudden it becomes easier to turn, you just went into that “plasticized” zone (provided you have not stripped the threads), and the bolt is now being stretched beyond its design parameters.

A common way to protect the integrity of a clamped joint is to simply use a longer fastener. The normal equation for grip length is to have 12 times the diameter of the fastener in length, to allow for the correct stretch but comfortably work within the “elastic” working range. (By the way, another minimum parameter to look out for is that at least three (but preferably five) threads engage in the joint.

Now that we have established that we need to achieve a correct clamping force, stayed tuned for Part 2 where I discuss how to get there!

Precision Maintenance: The Torque Wrench. Check Out These 15 Helpful Tips!