COURSE OVERVIEW:

Precision alignment of rotating machinery is a fundamental requirement for the reliable operation of industrial drive trains, including pump-motor sets, compressors, and turbines. This course provides an in-depth exploration of the geometric relationships between coupled shafts and the mechanical consequences of misalignment, such as increased vibration, bearing failure, and seal degradation. Understanding the physics of shaft movement under various loads is essential for achieving the tight tolerances required by modern high-speed equipment.

The scope of this training involves a comprehensive study of traditional and modern alignment techniques, ranging from rim-and-face dial indicator methods to advanced laser optical systems. Participants will examine the mathematical foundations of alignment calculations, focusing on the compensation for thermal growth, "soft foot" conditions, and piping strain. The coverage extends to the practical application of alignment tools in challenging environments, including vertical machines and multi-machine trains with intermediate spacers.

Furthermore, the course addresses the systematic troubleshooting of alignment-related issues that persist after initial corrections. It delves into the use of specialized software for modeling machine movement and the application of vibration analysis to confirm the success of the alignment process. By focusing on both the theoretical accuracy of the measurements and the practicalities of moving heavy machinery, this course provides the expertise necessary to eliminate one of the most common causes of machinery downtime.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Explain the different types of misalignment: Offset, Angular, and Skew.
2. Perform precise "soft foot" detection and correction procedures.
3. Utilize dial indicators for the Reverse Rim-and-Face alignment method.
4. Operate advanced laser alignment systems for horizontal and vertical shafts.
5. Calculate thermal growth compensations for hot-running equipment.
6. Analyze the impact of piping strain on machinery alignment integrity.
7. Implement alignment tolerances based on machine RPM and coupling type.
8. Troubleshoot recurring misalignment issues using vibration signature analysis.
9. Align multi-unit machine trains with multiple coupling interfaces.
10. Apply shim techniques and bolt-bound/base-bound solution strategies.
11. Execute alignment on cardan-shaft and spacer-coupling configurations.
12. Document alignment results and generate professional technical reports.
13. Evaluate the effect of foundation and baseplate condition on alignment.
14. Develop standardized alignment procedures for a maintenance department.

TARGET AUDIENCE:

This course is intended for mechanical technicians, maintenance engineers, millwrights, and reliability specialists responsible for the installation and upkeep of rotating equipment.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.