COURSE OVERVIEW:

Rotating equipment alignment and balancing are the two most critical factors in determining the lifespan and efficiency of industrial machinery. Precise alignment ensures that the centerlines of coupled shafts are collinear under operating conditions, minimizing the parasitic loads that destroy bearings, seals, and couplings. Similarly, balancing involves the procedure of checking the mass distribution of a rotor and adjusting it to ensure that the vibration of the journals and the forces on the bearings at operating speed are within specified limits. Together, these practices form the foundation of mechanical reliability for pumps, motors, compressors, and turbines.

The scope of this course covers the theoretical physics of centrifugal force and shaft dynamics alongside the practical mastery of modern measurement tools. Participants will explore the nuances of "thermal growth," where machines change position as they reach operating temperatures, and learn how to calculate the necessary "cold offsets." The coverage also includes a detailed look at the different types of unbalanced static, couple, and dynamic, and the mathematical vectors required to correct them. Through hands-on principles, the course addresses the common pitfalls that lead to "soft foot" and other installation errors that mask true alignment issues.

Furthermore, this training program emphasizes the use of laser alignment systems and digital balancing instruments, which have revolutionized the precision achievable in the field. Participants will learn how to interpret vibration signatures to distinguish between alignment and balance problems, ensuring accurate diagnostics before corrective action is taken. By the end of the course, attendees will be capable of performing precision setups that reduce energy consumption, lower noise levels, and dramatically extend the mean time between failures for all rotating assets in a process plant.

COURSE OBJECTIVES:

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

1. Explain the fundamental principles of shaft alignment and its impact on machine life.
2. Differentiate between offset and angular misalignment in horizontal and vertical planes.
3. Identify the symptoms of imbalance in rotating machinery via vibration analysis.
4. Perform comprehensive "soft foot" detection and correction procedures.
5. Apply the "Rim and Face" and "Reverse Indicator" methods using dial gauges.
6. Utilize modern laser alignment tools for high-precision shaft setup.
7. Calculate thermal growth compensations for equipment operating at high temperatures.
8. Distinguish between static, couple, and dynamic imbalance.
9. Conduct single-plane and two-plane field balancing using vibration analyzers.
10. Select the correct coupling types based on alignment capabilities and requirements.
11. Apply ISO 1940 standards for balanced quality grades.
12. Execute proper shimming and bolt-torquing sequences for stable machinery bases.
13. Troubleshot "resonance" issues that mimic unbalanced symptoms.
14. Document alignment and balancing results for compliance and reliability tracking.

TARGET AUDIENCE:

This course is ideal for Millwrights, Mechanical Technicians, Maintenance Engineers, Vibration Analysts, and Supervisors responsible for the installation and upkeep of rotating machinery.

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.