Updated from June 2023

Proper alignment of industrial equipment is one of the most overlooked, yet critical, factors in long-term machinery performance. Misalignment causes vibration, premature wear, and increased energy consumption. It’s a problem that affects every industry that relies on rotating or reciprocating equipment.

In this guide, we explain the most common causes of machinery misalignment, its consequences, and effective machinery alignment techniques to keep your assets running smoothly.

What Is Machinery Misalignment?

Machinery misalignment occurs when the shaft centres of coupled machines (like a motor and a pump) are not collinear. Misalignment can be angular, parallel, or a combination of both. Even small deviations can lead to major issues over time.

Causes of Machinery Misalignment

Understanding the causes of machinery misalignment is the first step to prevention:

• Improper Installation: If baseplates or foundations are not level during installation, the connected equipment will start off misaligned.
• Thermal Expansion: Changes in operating temperature can alter alignment conditions, particularly in high-heat environments.
• Foundation Settlement: Uneven or unstable foundations will shift over time, pulling equipment out of alignment.
• Pipe Strain: Connecting rigid pipework without flexible couplings or proper stress analysis can twist machines out of position.

These conditions are common in industrial processing plants, mining sites, and power stations, all of which are exposed to heavy loads, vibration, and thermal cycling.

Effects of Misalignment on Machinery

The effects of misalignment on machinery are rarely immediate, but they are always costly:

• Increased Vibration: Misalignment produces abnormal vibration patterns, leading to fatigue and eventual component failure.
• Seal and Bearing Damage: Excess loads on bearings and seals shorten their service life and increase the chance of lubricant leakage.
• Higher Energy Use: Misaligned machines require more energy to overcome additional friction and resistance.
• Unexpected Downtime: Alignment issues often cause unplanned stoppages, particularly in high-speed or continuous-run operations.

Machinery Alignment Techniques

A reliable machine alignment process starts with precise measurement. Common machinery alignment techniques include:

• Straightedge and Feeler Gauge: Still used for basic installations, though not recommended for critical or high-speed equipment.
• Dial Indicator Method: A more accurate analogue method that can detect small deviations.
• Laser Alignment Systems: Industry-standard tools that offer real-time data and alignment accuracy within 0.001 mm.

Whichever method is chosen, the process should always be repeated after running the equipment at operating temperature to account for thermal growth.

Best Practices for Industrial Machine Alignment

Here are proven industrial machine alignment best practices:

1. Ensure Foundation Stability: Proper grout materials like epoxy ensure the base remains level and resists settlement.
2. Use Precision Tools: Laser alignment is fast, accurate, and offers documentation for quality assurance.
3. Train Personnel: A well-trained technician understands how to detect early signs of machinery misalignment.
4. Check Pipe Strain: Always conduct stress tests on connected piping to avoid external loads.
5. Incorporate in PM Schedules: Make alignment checks part of your preventive maintenance strategy.

When to Involve a Specialist

If you notice repeated bearing failures, abnormal noise, or premature coupling wear, it’s time to consult a foundation and alignment specialist. Many alignment issues stem from below the machinery itself, an uneven grout bed, deteriorating sole plates, or even anchor bolt movement can all affect shaft position.

Alphatec Engineering specialises in foundation alignment for rotating equipment and precision alignment in heavy industry. Our services combine advanced diagnostics, in-house grout technology, and experienced field teams to deliver permanent solutions to misalignment problems.

Conclusion

Proper alignment is essential for maintaining the performance and lifespan of industrial machinery. By following machinery alignment best practices and understanding the common causes of misalignment, plant managers can reduce energy consumption, avoid costly downtime, and maximise ROI on capital equipment.

If your equipment is vibrating, losing performance, or suffering from repeat failures, it might be an alignment issue.