Shaft Alignment Training Course

Lesson 1 • Coupling Types and Alignment Sensitivity

Compares flexible, rigid, gear, disc, and jaw couplings by their misalignment accommodation and failure modes. Guides coupling selection for alignment-critical applications.

Lesson 2 • Baseplate and Grouting Inspection

Teaches inspection of baseplates and grout for voids, cracks, and looseness before alignment begins. Poor foundations invalidate alignment corrections and must be addressed first.

Lesson 3 • Thermal Growth and Operating Conditions

Explains how temperature changes shift shaft centre lines from cold to hot running conditions. Students calculate thermal offsets and incorporate them into alignment targets.

Lesson 4 • Driver and Driven Machine Identification

Defines driver and driven machine roles and explains why the driven machine is typically the fixed reference. Establishes the correction convention used in all alignment methods.

Lesson 1 • Types of Shaft Misalignment

Distinguishes parallel, angular, and combined misalignment in both vertical and horizontal planes. Provides the vocabulary used throughout the course.

Lesson 2 • Alignment Tolerances and Standards

Introduces industry-accepted tolerance ranges for different machine speeds and coupling types. Students learn to read tolerance tables and apply acceptance criteria.

Lesson 3 • Overview of Alignment Methods

Surveys straightedge, dial indicator, reverse-dial, and laser alignment methods at a high level. Sets the stage for detailed method instruction in later chapters.

Lesson 4 • Common Causes of Misalignment

Identifies installation errors, thermal growth, pipe strain, and soft foot as primary misalignment sources. Links root causes to corrective strategies introduced later.

Lesson 1 • Correcting Soft Foot Conditions

Guides students through shimming, machining, or grinding feet to achieve uniform contact at all four feet. Correction sequence prevents reintroducing soft foot during the process.

Lesson 2 • Soft Foot Detection Techniques

Covers dial indicator and laser-based methods for detecting soft foot at each machine foot. Students perform sequential foot-lift tests and interpret indicator readings.

Lesson 3 • Shim Selection and Preparation

Teaches proper shim material selection, thickness measurement, and preparation to avoid introducing new errors. Covers stainless steel, brass, and pre-cut shim packs.

Lesson 4 • Documenting Soft Foot Results

Establishes documentation standards for recording pre- and post-correction soft foot readings. Accurate records support quality assurance and future troubleshooting.

Lesson 1 • Making and Verifying Corrections

Guides students through shimming vertical corrections and making horizontal moves with precision. Verification readings confirm the machine is within tolerance before reassembly.

Lesson 2 • Graphical Alignment Plotting

Teaches the shaft alignment graph method to visualise machine positions and determine correction moves. Graphical plotting reduces calculation errors and aids communication.

Lesson 3 • Reverse-Dial Indicator Method

Introduces the reverse-dial setup using two indicators mounted on opposing shafts. This method eliminates face reading errors and suits long-span shaft arrangements.

Lesson 4 • Rim-and-Face Method

Teaches the rim-and-face procedure for measuring angular and offset misalignment simultaneously. Students record four-position readings and calculate required corrections.

Lesson 1 • Iterative Correction and Convergence

Teaches a systematic iteration strategy to converge on final alignment within the fewest correction cycles. Students recognize when additional iterations are needed versus when to stop.

Lesson 2 • Vertical Correction by Shimming

Translates alignment readings into exact shim thickness changes at each machine foot. Correct shim arithmetic prevents overcorrection and repeated iteration cycles.

Lesson 3 • Horizontal Correction Techniques

Covers the use of jack bolts, pry bars, and precision positioning tools for lateral machine movement. Students control horizontal moves to within required tolerance limits.

Lesson 4 • Bolt-Bound and Base-Bound Conditions

Identifies situations where machine feet reach the limits of horizontal or vertical adjustment range. Students apply remediation strategies to restore correction range.

Lesson 1 • Interpreting Laser System Results

Explains how laser software displays offset, angle, and foot correction values in real time. Students read result screens, identify out-of-tolerance conditions, and plan corrections.

Lesson 2 • Laser Alignment System Components

Identifies laser transmitter, receiver, display unit, and mounting hardware for common laser systems. Understanding each component ensures correct assembly and reliable measurements.

Lesson 3 • Measurement Procedures

Teaches the three-point and continuous sweep measurement modes used by laser systems. Students select the appropriate mode and execute measurements with minimal error.

Lesson 4 • System Setup and Mounting

Covers secure bracket attachment, laser beam alignment to the receiver, and initial system configuration. Proper mounting eliminates bracket-induced errors before measurement begins.

Lesson 1 • Vertical Machine Alignment

Addresses the unique challenges of aligning vertically oriented pumps, mixers, and motors. Gravity effects and limited access require modified measurement and correction approaches.

Lesson 2 • Multi-Element Machine Train Alignment

Extends two-machine alignment principles to three or more machines in a drive train. Students establish a reference machine and align each subsequent machine in sequence.

Lesson 3 • Spacer Shaft and Long-Span Alignment

Covers alignment of machines connected by spacer shafts or long flexible couplings where standard brackets cannot span the gap. Specialized fixtures and calculation adjustments are required.

Lesson 4 • Gearbox and Right-Angle Drive Alignment

Addresses alignment of gearboxes with multiple shaft extensions and right-angle drive configurations. Students manage multiple alignment planes and shaft orientation changes simultaneously.

Lesson 1 • Alignment History and Trend Analysis

Shows how to use historical alignment records to identify recurring misalignment patterns and root causes. Trend data drives proactive maintenance decisions and reduces repeat failures.

Lesson 2 • Integration with Reliability Programs

Connects alignment documentation to broader predictive and preventive maintenance programs. Students understand how alignment data feeds vibration analysis, lubrication, and asset management systems.

Lesson 3 • Pre-Alignment Inspection Records

Defines the data to collect before alignment begins, including soft foot, baseplate condition, and coupling inspection results. Complete pre-work records establish a defensible baseline.

Lesson 4 • Alignment Data Sheets and Reports

Teaches completion of standardized alignment data sheets capturing before, during, and after readings. Consistent report formats enable trend analysis across multiple alignment events.