COURSE OVERVIEW:

Achieving precision alignment is a fundamental requirement for the reliable operation of high-speed rotating machinery. This course provides an intensive technical exploration of the two most accurate methods used in the industry today: the Reverse Dial Indicator method and Laser Alignment technology. Participants will examine the geometric principles that allow these techniques to overcome the limitations of traditional "Rim and Face" methods, ensuring that the rotational axes of coupled shafts are perfectly collinear under operating conditions.

The scope of this training encompasses the mathematical foundations of the reverse indicator sequence, including the use of graphical plotting and calculation formulas to determine necessary machinery moves. We will transition from manual dial techniques to the application of advanced laser systems, exploring how digital sensors and software streamline the alignment process while reducing human error. The course emphasizes the preparation phase, addressing critical factors such as bracket sag, thermal growth compensation, and the elimination of external stressors like piping strain.

Coverage includes hands-on methodologies for correcting both parallel and angular misalignment in horizontal and vertical planes. Attendees will learn how to handle complex alignment scenarios, such as spacer shafts and machine trains with multiple coupling points. By mastering these advanced techniques, participants will be able to significantly reduce vibration-related failures, extend the life of bearings and mechanical seals, and improve the energy efficiency of their plant’s rotating assets.

COURSE OBJECTIVES:

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

• Explain the geometric superiority of Reverse Alignment over traditional methods.
• Calculate and compensate for the indicator bracket sag in the field.
• Execute a complete Reverse Dial Indicator alignment procedure.
• Utilize graphical plotting techniques to visualize shaft positions.
• Set up and calibrate modern Laser Alignment systems correctly.
• Interpret laser sensor data to perform precision machinery moves.
• Distinguish between "Static" and "Dynamic" alignment requirements.
• Apply thermal growth offsets to account for machinery expansion.
• Identify and correct "Soft Foot" conditions using digital and manual tools.
• Calculate shim requirements for vertical corrections with high precision.
• Perform horizontal moves using jackscrews and real-time monitoring.
• Align machinery trains involving more than two coupled units.
• Document alignment results according to international industry standards.
• Troubleshoot common errors in laser signal transmission and reception.

TARGET AUDIENCE:

Mechanical Technicians, Millwrights, Reliability Engineers, Maintenance Supervisors, and Rotating Equipment Specialists.

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.