Aux 1 Unit 12 Q3

Aligning a new motor with an existing pump is a crucial process to ensure smooth power transmission, minimize wear and tear on components, and prevent vibrations that can lead to premature failure and operational issues. Here’s a description of the typical alignment procedure:  

1. Tips for Correcting Pump Shaft Misalignment – Pumpworks

Tools and Equipment:

• Alignment Tools: The choice of alignment tools depends on the desired level of accuracy and the complexity of the system. Common tools include:
  • Feeler Gauges: Used for basic gap and sag measurements between coupling faces.   1. How to Align the Coupling Between the Motor and a Corken Pump – YouTube www.youtube.com
  • Dial Indicators: Provide more precise measurements of shaft runout and misalignment.   1. Useful information on pump alignment – Michael-Smith-Engineers.co.uk www.michael-smith-engineers.co.uk
  • Laser Alignment Systems: Offer the highest accuracy and real-time feedback during adjustments, but they are also the most expensive option.
• Other Tools: Additional tools might be required depending on the specific setup, such as shims, wrenches, spirit levels, and measuring tape.

Safety Precautions:

• Isolation: Ensure the system is de-energized and isolated from its power source using lockout/tagout procedures.
• Rotating Parts: Be cautious of rotating parts, especially when the motor is turned during alignment checks.

Alignment Procedure:

1. Initial Checks:

• Coupling Type: Identify the type of coupling used (rigid, flexible) as this will influence the allowable misalignment tolerances.
• Soft Foot: Check for “soft foot,” where one or more of the motor’s feet are not making full contact with the baseplate, causing uneven loading and affecting alignment. This can be corrected by shimming under the motor feet.   1. Useful information on pump alignment – Michael-Smith-Engineers.co.uk www.michael-smith-engineers.co.uk2. The 4 different types of soft foot | Easy-Laser easylaser.com

2. Rough Alignment:

• Visual Inspection: Visually inspect the motor and pump shafts for any obvious misalignment or offset.
• Coarse Adjustment: Make initial adjustments to the motor position using shims or adjusting bolts to bring the shafts as close to alignment as possible.

3. Precise Alignment:

• Measurement and Adjustment: Use the chosen alignment tools (feeler gauges, dial indicators, or laser alignment system) to measure the misalignment between the motor and pump shafts in both the vertical and horizontal planes.
• Angular and Offset Misalignment: The measurements will reveal any angular misalignment (shafts not parallel) and offset misalignment (shafts parallel but offset).
• Iterative Adjustments: Make incremental adjustments to the motor position (using shims or adjusting bolts) to correct both angular and offset misalignment, referring to the tool’s readings and the coupling manufacturer’s alignment tolerances.
• Repeat Measurements: After each adjustment, re-measure the alignment to ensure the corrections are effective and within tolerance.   1. What is Pump Alignment? A Complete Guide – Pruftechnik Blog – blog.pruftechnik.com

4. Final Checks:

• Tighten Bolts: Once the desired alignment is achieved, tighten all the motor mounting bolts securely.
• Re-check Alignment: It’s good practice to re-check the alignment after tightening the bolts to ensure it hasn’t shifted.
• Run Test: If possible, run the motor and pump at low speed and observe for any unusual vibrations or noise that might indicate residual misalignment.

Key Considerations:

• Coupling Manufacturer’s Specifications: Always refer to the coupling manufacturer’s specifications for the allowable misalignment tolerances.
• Thermal Growth: If the system operates at elevated temperatures, consider the potential for thermal growth of the components and adjust the alignment accordingly.
• Soft Foot Correction: Addressing soft foot issues is crucial before proceeding with precise alignment.
• Qualified Personnel: Alignment should ideally be performed by trained personnel with experience in using alignment tools and understanding the specific requirements of the system.

By following these steps and using appropriate alignment tools, you can ensure the new motor is correctly aligned with the existing pump. This will lead to smoother operation, reduced wear and tear, improved efficiency, and a longer lifespan for both the motor and pump.

After aligning a new motor to an existing pump, several crucial checks should be performed before putting the pump back into operation. These checks help ensure the alignment was successful, the system is safe to operate, and there are no potential issues that could lead to damage or malfunctions.

Here’s a list of recommended checks:

1. Re-check Alignment:

• Importance: It’s good practice to re-check the alignment after tightening the motor mounting bolts, as tightening can sometimes cause slight shifts in the alignment.   1. What is Pump Alignment? A Complete Guide – Pruftechnik Blog – blog.pruftechnik.com
• Method: Use the same alignment tools used during the initial alignment process (feeler gauges, dial indicators, or laser alignment system) to verify that the alignment is still within tolerance.

2. Visual Inspection:

• Coupling: Visually inspect the coupling for any signs of damage, wear, or misalignment. Ensure all bolts or fasteners are properly tightened.
• Piping and Connections: Check all piping and connections for leaks, loose fittings, or any signs of stress or strain.
• Motor and Pump: Inspect the motor and pump for any visible damage, loose components, or abnormal conditions.

3. Lubrication:

• Oil Level: Check the oil level in the pump’s bearings and reservoir (if applicable), ensuring it’s within the recommended range.
• Oil Condition: Inspect the oil for signs of contamination or degradation. If necessary, replace the oil with fresh oil that meets the manufacturer’s specifications.

4. Electrical Connections:

• Tightness and Security: Ensure all electrical connections to the motor are tight, secure, and free of corrosion.
• Grounding: Verify proper grounding of the motor and control panel.

5. Initial Run Test:

• Low Speed and No Load: Start the motor and pump at a low speed and without any load on the pump.
• Monitor for Vibrations and Noise: Carefully observe and listen for any unusual vibrations or noise, which could indicate residual misalignment or other issues.
• Check for Leaks: Inspect the pump, coupling, and piping for any leaks during operation.

6. Gradual Load Increase:

• Stepwise Increase: Gradually increase the load on the pump, monitoring its performance and any changes in vibration or noise levels.
• Temperature Monitoring: Monitor the temperature of the bearings and other critical components during the load increase.
• Stop if Issues Arise: If any abnormal vibrations, noise, leaks, or excessive temperature rise are observed, stop the pump immediately and investigate the cause.

7. Documentation:

• Record Findings: Document the results of all checks and tests in the maintenance log.
• Operational Parameters: Record the normal operating parameters (current, voltage, temperature, vibration levels) for future reference and comparison.

Additional Considerations:

• Specific Instructions: Refer to the pump and motor manufacturer’s instructions for any specific pre-start checks or recommendations.
• Safety: Always prioritize safety when working with rotating machinery and electrical equipment. Follow proper procedures and use appropriate PPE.

By conducting these checks and following a cautious startup procedure, you can ensure that the newly aligned motor and pump system operates safely, efficiently, and without any issues, minimizing the risk of damage and maximizing its service life.