(a) Aligning a New Motor with an Existing Pump
Aligning a new motor with an existing pump ensures the shafts of both machines are in proper alignment to minimize vibration, wear, and improve overall efficiency. Here’s a breakdown of the process:
Preparation:
- Lockout and Tagout: Implement proper lockout/tagout procedures to ensure safety and prevent accidental energization.
- Mounting: Securely mount the new motor on the foundation or frame, following the manufacturer’s instructions.
- Shaft Cleaning: Clean the motor and pump shafts to remove any dirt or debris that could affect the alignment process.
Alignment Procedure (There are multiple methods, here’s a common one):
- Dial Indicators: Attach dial indicators to brackets on the pump and motor shafts. These indicators will measure any runout (wobble) or misalignment between the shafts.
- Shimming: Loosen the motor mounting bolts slightly. Use shims (thin wedges of metal) placed strategically between the motor feet and the foundation to adjust the motor’s position.
- Dial Gauge Readings: By turning the shafts and observing the dial indicator readings, the technician can adjust the shims to minimize both horizontal and vertical misalignment between the shafts.
- Alignment Tolerances: Tighten the motor mounting bolts to the specified torque values. Re-check the dial indicator readings to ensure they fall within the acceptable alignment tolerances specified by the pump and motor manufacturers.
Additional Techniques:
- Laser Alignment: In some cases, laser alignment tools might be used for a more precise alignment process. These systems project laser beams onto targets on the shafts and provide real-time data on misalignment.
Important Notes:
- The specific alignment procedure will vary depending on the type of pump, motor, and the chosen alignment method.
- Always follow the manufacturer’s instructions for both the pump and motor regarding alignment procedures and acceptable tolerances.
- The process requires proper training and experience to ensure accurate alignment.
(b) Checks Before Using the Pump After Alignment
Before operating the pump after motor alignment, it’s crucial to perform some final checks to ensure everything is in order:
- Recheck Alignment: While unlikely, it’s good practice to perform a final verification of the alignment after tightening the motor mounting bolts. This ensures any slight movement during tightening hasn’t affected the alignment.
- Lubrication: Verify that the pump is properly lubricated according to the manufacturer’s recommendations. This includes checking oil levels (if applicable) and ensuring grease points are lubricated.
- Coupling Inspection: Visually inspect the coupling between the motor and pump shaft for any signs of damage or wear. Ensure all coupling bolts are tightened to the specified torque values.
- Pipework: Double-check that all piping connections to the pump are secure and free of leaks. Ensure proper venting of any air pockets within the piping system.
- Electrical Connections: Verify that all electrical connections to the motor are secure and meet the required specifications.
By performing these checks before starting the pump, you can help ensure safe and reliable operation.