The compressor gearbox is the most critical piece of equipment in most industries. They provide for the increase or reduction of the compressor speed and torque. Proper alignment of these gearboxes makes them run efficiently and smoothly. They will result in huge problems if misplaced. In this blog, we are going to tell you how accurate alignment of your compressor gearbox is important to you and why it maximises performance and avoids damage.
What Is Compressor Gearbox Alignment?
Alignment is the process of making the compressor and gearbox shafts straight. When the two shafts are in proper alignment, they rotate freely. There is no additional stress on the system. When the shafts are not properly in place, it is called misalignment. Misalignment can cause vibration. It can also create noise, increase wear, and even lead to equipment failure.
There are two forms of misalignment:
- Parallel misalignment – When the shafts are not aligned but parallel to one another.
- Angular misalignment – When the shafts are at an angle to one another rather than straight.
Both forms of misalignment can impair the operation and lifespan of your compressor gearbox.
Benefits of Proper Alignment
1. Longer Equipment Life
Correct alignment minimises excessive stress on the gearbox, bearings, and other parts. When the load is evenly shared within the system, the components last longer. This minimises the requirement for repetitive replacement.
2. Reduced Vibration and Noise
Misaligned gearboxes produce unwanted vibration and noise. Not only does this compromise the level of comfort in the workplace, but it also ruins the equipment in the long run. Smooth operation is found with proper alignment, which minimises such undesired effects.
3. Improved Efficiency
When the gear case and compressor shafts are aligned at the same time, energy wastage is reduced. This implies that the motor does not have to exert extra effort in an attempt to compensate for resistance. Therefore, the system becomes efficient, conserves power, and lowers the cost of energy.
4. Lower Maintenance Cost
Accurate alignment prevents seal, bearing, and gear damage. This minimises the risk of breakdowns and unplanned maintenance. It saves time and money in the long term.
5. Enhanced Safety
Misaligned or vibrating, noisy equipment can be hazardous to work around. Accurate alignment provides a safer working environment with smooth, dependable equipment.
Why Does Misalignment Occur?
There are several reasons that a compressor gearbox may become misaligned:
- Wrong installation – The unit is not properly installed initially, and it may result in misalignment.
- Thermal expansion – Temperature changes can cause parts to expand or contract, and this can alter the alignment.
- War and tear – The parts over time can shift or loosen, and this can cause the shafts to get misaligned.
- Foundation issues – If the machine’s foundation is not firm or level, it leads to vibration and misalignment.
- Accidental shifting or bumping – While repairing or cleaning, the machines can slightly shift, disrupting alignment.
Misalignment Signs
Several signs will inform you whether your compressor gearbox is misaligned:
- Increased noise or vibration
- Seal leakage
- Excessive bearing or coupling temperature
- Wearing unevenly on components
- Poor performance
To validate the problem, the shafts can be verified by tools such as laser alignment systems, dial indicators, or straight edges. These tools assist in validating whether the shafts are aligned and the amount of misalignment.
Steps of Proper Alignment
1. Laser Alignment
This is the most precise and up-to-date technique. A trusted compressor and parts company often employs a laser beam to detect the alignment of the shafts, helping in identifying even minute misalignments. Laser alignment is rapid, accurate, and dependable.
2. Dial Indicators
This is a more traditional technique, but still prevalent in many places. This technique involves fixing a dial gauge to a shaft and then rotating the same to check alignment. Although it requires more time and skill, it will suffice well enough as long as it’s applied practically.
3. Straight Edge and Feeler Gauges
This is the easiest technique. A metal strip is merely used to test whether the shafts are in alignment. Feeler gauges are used for gap checking. Although less precise than a laser or dial, this can be employed for approximate alignment.
How Frequently Should You Inspect Alignment?
Alignment must be inspected every now and then to ensure your gearbox remains smooth. Alignment must be inspected:
- During the new machine installation
- After the machinery has been relocated
- During normal maintenance
- When there is a temperature change
- If abnormal vibration or noise occurs
A scheduled maintenance routine with periodic checks for alignment can avoid issues before they become serious.
Role of Professionals
Correct alignment is a professional’s work. It needs knowledge, tools, and experience. This is why it is always better to appoint trained professionals for the job of alignment. They can identify the issue correctly and correct it accordingly. Tampering with it without tools or training will make things worse.
Conclusion
In brief, the correct alignment of your compressor gearbox is crucial. It enhances performance, conserves energy, and prevents system damage. Misalignment, no matter how slight, can cause enormous issues in the long run. By inspecting and ensuring regular alignment, you can keep your equipment running smoothly and safely.
If you are not certain of your gearbox alignment, it is always best to have a professional call. Aligning today with Capco USA will save you a lot of time, money, and hassle later on. So, make it part of your routine maintenance regimen and keep your compressor gearbox in good condition.
