WO2002003029A1

WO2002003029A1 - Machinery alignment method and apparatus

Info

Publication number: WO2002003029A1
Application number: PCT/US2000/018267
Authority: WO
Inventors: John M. Zatezalo
Original assignee: Alignment Solutions Llc
Priority date: 2000-06-30
Filing date: 2000-06-30
Publication date: 2002-01-10
Also published as: AU2000260661A1

Abstract

A method and apparatus are provided for performing hot and cold alignment checks of coupled, rotating machines (281, 28n). The alignment check includes compensation for thermal growth (62) and dynamic movement (63), as appropriate. The alignment measuring device (26) provides readings that are converted to values of angularity and off set. The converted values of angularity and off set, as adjusted by the thermal growth and other factors, is compared to a cold alignment specification to determine if alignment of the machines is warranted. The thermal growth and dynamic movement factors are estimated or derived empirically, using graphical user interfaces. The method and apparatus provide suggested movement values to align a machine.

Description

MACHINERY ALIGNMENT METHOD AND APPARATUS

Field of the Invention

The invention is a method and an apparatus for aligning rotating machinery,

hi particular, the invention is a method for performing alignment checks, including

hot alignment checks on rotating, coupled machines. Background Art

When two or more rotating machine shafts are coupled, the shafts should be

aligned to withing predetermined tolerances in order to ensure optimum performance of the machines, and to reduce vibration and possible damage to the machines. For

many machinery arrangements, the optimum alignment exists when the axes or

rotation of all the shafts coincide along a straight line that extends through each such

axis of rotation.

A number of shaft alignment methods are available to perform shaft

alignments. These method generally involve placement of jigs, measuring devices and

other components on or near the shafts in order to take measurements that can then be used to compute shaft misalignment. The measuring devices may be direct reading

instruments such as dial indicators. Other measuring devices employ lasers to measure misalignment.

Most current alignment systems are complicated arrangements that require

significant time to install, require experience and expertise to operate, and are

susceptible to erroneous results due to a combination of operator error and

environmental factors. These environmental factors include overhung rotor effect, journal movements, effect of gravity on the measurement apparatus, and atmospheric

interference with laser and other optical systems, for example. Moreover, these systems are only capable of cold alignment checks, and so cannot empirically account for environmental effects such as thermal growth, for example. Summary of the Invention

This invention provides a method and apparatus for aligning coupled, rotating machines. The invention may be sued with any alignment check measurement device. The invention may use data collected by optical alignment systems, laser systems, rim and face mechanical systems and other alignment systems. The invention is particularly suited for use with EZ-Line™ and ICAD™ (Integrated Coupling and Alignment Device). These later systems are described in detail in copending U.S. Patent Application Serial NO. 08/949,187, entitled METHOD AND APPARATUS FOR MEASURING AND ADJUSTING FOR SHAFT MISALIGNMENT IN POWER EQUIPMENT.

The invention provides the ability to conduct true hot alignment checks of rotating coupled machines. The invention may also be used to perform cold alignment checks. A hot alignment check requires that the machines being measured be at or very near to their normal operating temperature (i.e., hot). The machines must be hot because the metal structure and components of a machine will expand, or grow, with rising temperature. When a machine expands, the change in machine dimensions may impart a displacement of the rotors, or shafts of the machines. If the machines are then operated with this misalignment uncorrected, then the machines may suffer damage such as bearing failure, for example, or may operate inefficiently, thereby wasting energy. Thermal growth may be estimated. However, hot alignment checks may be preferred over cold alignment checks because the hot alignment checks mclude empirically derived values for thermal growth of the involved machines. Unless the thermal growth is provided as a direct result of measurement, any estimated values of thermal growth are only speculative, and in the field, may be spectacularly inaccurate. Current systems that require extensive set up and calibration of the measurement devices in order to ensure accurate results. The set up time insures that the involved machines will cool down to ambient temperature, thereby making a hot alignment check impossible to perform.

The invention produces hot alignment check values and cold alignment check values based initially on estimates, and subsequently on empirical data. The hot alignment check is conducted when the machine is in its normal, hot condition, hot shutdown. Thus, the hot alignment check values will include a compensation for dynamic movement. The cold alignment check values include compensation for thermal growth and dynamic movement. A machine aligned to the cold alignment check values should be in "perfect" alignment when operating, and should be within the required hot alignment check values, as adjusted by the dynamic movement factors.

The invention also computes a potential load factor for each of the coupled machines, the load factor is related to the potential amount of torque that is "lost" due to misalignment. A torque vector may be defined that is coincident with the axis or rotation of a first machine rotor. If this machine is misaligned with respect to a second machine rotor, then some fraction of the torque vector is not available to drive the second machine rotor. The "lost torque" is the torque vector generated by the first machine times the sine of the angle created by the misalignment of the first and the second machine rotors.

The invention computes the torque vectors and lost torque values, and displays the results. The invention also computes a cost measure corresponding to the potential load factor. The cost measure represents the potential energy cost associated with the misaligned machines.

The invention also provides graphical user interfaces (GUIs) that allow an operator to view, modify, add and delete data for machinery units requiring precise alignment. The GUIs present alignment results for hot and cold alignment check conditions, measures of angularity and off set, and suggested movements to bring the machinery unit into alignment. Brief Description Of The Drawings

Following is a brief description of the several drawings, wherein like numerals refer to like components, and wherein:

Figure 1(a) is logical representation of an alignment system;

Figure 1(b) is a logical representation of a database for use with the alignment system of Figure 1(a);

Figure 2 is a block diagram of representative hardware components that may be used with the alignment system of Figure 1(a);

Figure 3 is another block diagram of the major components of the alignment system;

Figure 4 is a block diagram of the engineer program;

Figure 5 is a block diagram of a unit log module;

Figure 6 is a block diagram of an information module;

Figure 7 is a block diagram of a machinery lengths module;

Figure 8 is a block diagram of a vertical change module;

Figure 9 is a block diagram of a horizontal change module;

Figure 10 is a block diagram of a chart selection module;

Figure 11 is a block diagram of a select data module;

Figure 12 is a block diagram of a cold alignment module;

Figure 13 is a block diagram of a hot alignment module;

Figure 14 is a block diagram of a last job module;

Figure 15 is a block diagram of a thermal growth module;

Figure 16 is a block diagram of a journal movement module;

Figure 17 is a block diagram of a coupling length module;

Figure 18 is a block diagram of an optical target module;

Figure 19 is a block diagram of an overhung rotor module;

Figure 20 is a block diagram of an uneven bearing module;

Figure 21 is a block diagram of the manager program; Figure 22 is a block diagram of the ICAD™ mechanic program;

Figure 23 is a block diagram of an embodiment of a local alignment unit;

Figure 24 is a block diagram of an alternate local alignment unit;

Figures 25(a) and 25(b) are a schematic of an embodiment of the ICAD™ device;

Figure 26 is a schematic of an embodiment of the EZ-Line™ device;

Figure 27 illustrates the computation of a torque vector;

Figure 28 is a flow diagram illustrating operation of the engineer program;

Figure 29 is a flow diagram illustrating operation of the manager program;

Figures 30(a) and 30(b) depict a machine unit and corresponding coordinate points vertically;

Figures 31(a) and 31(b) depict a machine unit and corresponding coordinate points horizontally;

Figures 32(a) and 32(b) are diagrams of points in a vertical plane and a horizontal plane;

Figure 33 is a flowchart of a method according to the present invention;

Figure 34 is a block diagram of a computer used with the mechanic program;

Figure 35 illustrates an alignment measurement device;

Figures 36(a) and 36(b) illustrate alignment measurements about a coupling face;

Figure 37 is a geometric interpretation of the alignment measurements illustrated in Figures 36(a) and 36(b);

Figure 38 illustrates alignment measurements concerning two machines;

Figure 39 is a geometric interpretation of the alignment measurements illustrated in Figure 38;

Figure 40 is another geometric interpretation of the alignment measurements illustrated in Figure 38; Figures 41 - 64 illustrate graphical user interfaces that may be used with the alignment system of Figure 1(a). Detailed Description

Coupled, rotating machines operate best when the machines are "aligned." The machines may be considered to be aligned when the axes of rotation of their shafts, or rotors coincide. The degree of alignment (or misalignment) may be determined by performing an alignment check. Ideally, such an alignment check would be conducted with the machines operating in their normal, hot operating conditions. However, determining alignment of a rotating shaft may be difficult. Cold alignment checks are more easily and safely performed because the machine shafts are static. Cold alignment checks, to be accurate, must account for thermal growth and dynamic movement, for example. These factors can be estimated, based on machinery data, or may be obtained empirically. Normally, empirical measurements produce more accurate results.

The results of an alignment check may indicate that one or more machines needs to be aligned (i.e., moved). Alignments are conducted with the machines in the cold, static condition. The machines to be aligned are aligned to cold alignment specifications. The cold alignment specifications differ from hot alignment specifications by such factors as thermal growth. Ideally, a machine that is aligned according to the cold alignment specifications will be, when operating in its normal, hot operating condition, aligned according to the hot alignment specification as adjusted by any dynamic movement factors.

Current alignment systems do not accurately account for the thermal growth and dynamic movement factors. Current alignment systems do not provide for use of empirical data, and do not permit accurate hot alignment checks to verify that the cold alignment was performed properly.

Figure 1(a) is a logical diagram of an alignment system 10 that is used to check (hot and cold) the alignment of and maintain the status of coupled, rotating machines. An engineering program 11 creates a database for a machinery unit that includes two or more coupled, rotating machines. The database contains all pertinent machinery information such as machinery dimensions, thermal growth, gear reactions, journal movements, effects of gravity on overhung rotors, horsepower, and other information related to the machines, for example. The engineering program 11 also includes the necessary information displays, data entry displays, and engineering assistance displays to allow the data to be entered and viewed in a consistent manner. The engineering program 11 calculates dynamic movements and thermal growth estimates. When empirical data are available, the engineering program 11 updates the database for a particular machinery unit to include these measured values.

A manager program 12 receives data from the engineer program 11, and provides a scheduling function to help ensure hot and cold alignment checks are completed. The manager program 12 also calculates a potential energy cost value based on a load factor. The load factor is related to the torque vectors produced by rotating machines. If the machines are not properly aligned, some amount of torque T, generated by a driving machine will be transmitted to a downstream machine in such a fashion that the torque T, is "lost", or applied in a direction orthogonal to the desired transmission path. This potential lost torque T, is not available to drive the downstream machines, and not only results in lost efficiency, but can also lead to vibration and damage to the machines.

The potential energy costs associated with the potential "lost" torque T, may be based on a given ratio of dollars per kilowatt, such as $0.10/kW, for example. Other factors, such as the coupling type (e.g., flexible), and machinery type (e.g., turbine, motor) may be used to calculate the energy costs.

A generic mechanic program 14 duplicates some of the functionality of the engineer program 11. The generic mechanic program 14 may be used with a specific combination of machines. For example, a first mechanic program may be created for a combination motor, gear box and compressor and a second mechanic program may be created for a turbine, gear box and generator. The program is referred to as generic in Figure 1(a) because it may be used with any system that measures alignment values. Thus, the generic mechanic program 14 may be used with a laser-based alignment system and a direct- reading dial indicator based system, for example. The generic mechanic program 14 may compute the amount of misalignment for coupled machinery units and the required adjustments to the machines, and may display the results, or provide the data to the engineer program 11.

An ICAD™ mechanic program 15 performs the same functions as the generic mechanic program 14, but is specifically adapted for use with an integrated coupling and alignment device (ICAD™) or and EZ-LINE™ alignment device. The ICAD™ and EZ-LINE™ devices are described in detail in copending U.S. Patent Application Serial No. 08/949,187 entitled METHOD AND APPARATUS FOR MEASURING AND ADJUSTING FOR SHAFT MISALIGNMENT IN POWER EQUIPMENT.

Alternately, single mechanic program 15 may be provided that includes the functionality of the generic mechanic program 14 and the ICAD™ mechanic program 15.

A mechanic file 16_i5 may be a copy of part of a larger database related to machinery units, and is shown separately to indicate that the file may be used in a mechanic program in a stand alone fashion at the local facility. The operation of the mechanic program at the local facility will be described in detail later.

Figure 1(b) illustrates a database 40 that can be used with the alignment system 10 of Figure 1(a). In particular, the database 40 may be used with either the engineer program 11 or one of the mechanic programs.

In Figure 1(b), the database 40 is shown comprising several files 40_;. The database 40 may be arranged in this fashion so that machinery units for a particular facility (e.g., a steel mill) may be arranged in one file. The database 40 includes a group identification 420. A group identification 420 is used to identify a particular machinery unit or grouping of machines. For example, a machinery unit could include a driving turbine, a gear box, and a pump. A number of components file 422 includes the separate number of components that exist within the machinery unit. In the example just given, the number of components would be 3, namely one for the turbine, one for the gear box, and one for the pump. A maximum rpm file 424 includes the maximum rpm for any machine in the machinery unit. A unit ID file 426; includes a separate file for each machine in the machinery unit. A machine ID file 426_; includes information that is specific to a particular machine.

A unit names file 428; exists for each machine in the machinery unit. The unit names file 428_; may contain the normal or generic name for a particular machine, such as a turbine. The gear box identification file 430 includes a data field that identifies a machine as a gear box. A driver H.P. file 432 defines the horsepower from the driving machinery unit. A H.P. transfer file 434; defines the power transferred at each coupling in the machinery unit.

An angularity and off set (A&O/S) tolerances file 436_; lists the angle and the off set that is allowed for each machine. A unit dimensions file 438; contains various unit dimensional data for each machine in the machinery unit. The unit dimensional data includes data such as distances between support members for a machine, distance from a front support member to a coupling flange, and vertical distance between the bottom of a support unit and the machine shaft, for example. A cold alignment value file 440; includes the amount of angularity and off set that exists for a particular machine when the machine is in a cold, static condition. A hot alignment value file 442; includes angularity and off set values for a particular machine when that machine is not rotating but is at its normal hot operating condition. An other data file 444 includes other data that may be of interest for personnel operating the machines.

A thermal growth file 446_; exists for each machine. The thermal growth file 446; includes expected and empirically derived data related to the expansion of the metal structure of each machine as the machine heats up from ambient conditions to its normal operating temperature. A journal movement file 448; includes the X and Y direction movement of a shaft in its journal bearing when a particular machine is operating at its normal operating load. A coupling length file 450; exists that expresses the coupling length for each coupling in the machinery unit. An overhung rotor file 452_; provides the mass and length of any rotating element that extends beyond its supporting journal bearing. The overhung rotor file 452; also includes diametrical data for each journal bearing. Finally, an uneven bearings file 454; includes diametrical information for all machines that have journal bearings with different diametrical clearances.

The data contained in the database 40 is useful for operating either the engineer program 11 or one of the mechanic programs. When a mechanic file 16 is created, appropriate portions of the database 40 are loaded, for example, onto a floppy disk to create the mechanic file 16_;.

Figure 2 shows hardware components of an alignment system 20 that may be used to measure misalignment in coupled, rotating machines, compute movements to remove the misalignment, and maintain a database of information related to the machines. In Figure 20, machines in the machinery units 28, - 28_n are coupled together, and may experience misalignment as a result of operation and other factors. A data measuring device 26 may be used to measure the amount of misalignment. The data measuring device 26 may be of a direct reading type such as a dial indicator, for example. The dial indicator includes an analog readout section having a dial and a faceplate with graduations corresponding to a displacement. A probe is slidably mounted in a sleeve and contacts a component to be measured. Displacement of the probe causes the dial to move so that the dial points to a value on the faceplate corresponding to the lateral displacement of the probe. An alternate data measuring device may be an electronic readout device, which provides a digital display that shows displacement of the probe. When this alternate measuring device, the movement of the probe is shown by a positive or negative value displayed at the readout device, or at some alternate location, for example. The data measuring device 26 is shown connected to a local unit 24 over signal path 25. The signal path 25 may be an RS-232 connection, for example. Alternately, the signal path 25 may include a telecommunications network such as a Public Switched Telephone Network (PSTN) and an Internet. The signal path 25 may also be a wireless signal path.

The local unit 24 receives data from the data measuring device 26 and may store and process the data. In an embodiment, the local unit 24 may be a personal computer (PC). The local unit 24 may also be a simple processor/data storage device with limited capability to provide a readout to an operator. The local unit 24 will be described in more detail later.

The local unit 24 may communicate with a remote unit 21 over a signal path 22 and a network 23. The signal path 23 can be any wired or wireless telecommunications path including a PSTN, an Ethernet, a fiber optic cable, a coaxial cable, a microwave path, and a radio channel, for example. The network 23 may be a telephone network, for example. The network 23 may also be the Internet, or any other telecommunications network capable of passing analog or digital data. Data from the local unit 24 may also be transferred to the remote unit 21 by recording the data on an appropriate data storage device, such as a floppy disk (not shown), for example, and transferring the data storage device to the remote unit 21.

The remote unit 21 includes processors, communications devices, memory devices, and peripheral devices to allow receipt, processing, storage and displaying of data received from the local unit 24. The remote unit 21 may be a PC, for example.

Figure 3 is a logical diagram that shows the interrelationship of the programs shown in Figure 1(a) with the remote unit 21 and the local unit 24 of Figure 2. The remote unit 21 includes a processor 30 that controls the functions of the remote unit 21. The processor 30 is coupled to a program memory 48. The program memory 48 stores operating programs for the engineer, manager and mechanic programs. That is, the memory stores the engineer program 11, the manager program 12, the generic mechanic program 14, the ICAD™ mechanic program 15, and third-party diagnostics 13. The databases 40; store data related to machinery units that are located at local sites. Several such databases 40; may exist in the remote unit 21. Data in the databases 40_; are used by the engineer, manager and mechanic programs.

The remote unit 21 includes an interface 42 for receiving the mechanic databases 16_;. The interface 42 may be a floppy disk drive, for example. In this case, the mechanic database 16_; data is recorded on a floppy disk that is transported to the remote unit 21. The remote unit 21 can also receive the data from the mechanic database 16_; by uplink from the local site. The local site and the remote site may send and receive data using a telecommunications system such as the PSTN or the Internet, for example. The remote unit 21 may include a high speed modem 41 or other communications device, such as an ISDN connector, for example, to receive data from and send data to the local site.

The remote unit 21 may be coupled to a number of peripheral devices that increase the functionality of the remote unit 21. The peripheral devices include an interface 45. The interface 45 may be a wired or wireless keyboard, a mouse or other pointing device such as a trackball or a touch sensitive screen. A printer or plotter 46 may also connect to the remote unit 21 to provide written reports or plots of machinery unit misalignment and suggested movements to correct the misalignment. A display 47, coupled with graphical user interfaces, may display machine data and alignment results.

The local unit 24 may include a local processor that processes data received from the data measuring device 26 according to a mechanic program such as the ICAD™ mechanic program 15. The local unit 24 is shown connected to the data measuring device 26 by way of the RS-232 connection and cable. An interface 49 connects the local unit 24 to the remote unit 21. The interface 49 may be a modem, such as a telephone modem, high speed cable modem, or a wireless modem, for example. The interface 49 may also be an ISDN connector and cable, or other connector and cable arrangement capable of transmitting analog or digital data.

Figure 4 is a logical diagram of the engineer program 11. Unlike current alignment systems, the engineer program 11 creates accurate alignment specifications, including both cold and hot conditions, necessary for dynamic alignment of coupled, rotating machinery. The first component of the engineer program 11 is a unit log module 51, which provides basic information regarding machinery units. An information module 52 is coupled to the unit log module 51, and is accessed directly from the unit log module 51. The information module 52 is used to enter data related to specific machines and to create the basic database structure used by the engineer program 11.

A data entry module 53 allows measurement data to be entered. The measurement data includes machinery lengths and expected vertical and horizontal changes. The expected vertical and horizontal changes are related to thermal growth and mechanical movements of the machines as the machines transition from a stopped, cold condition to an operational, hot condition. These data are entered using a machinery measurements module 54, a vertical changes module 55 and a horizontal changes module 56. Using these data, the engineer program 11 will compute a cold alignment specification chart and a hot alignment specification chart. The cold and hot alignment specification charts will be described in detail later. The cold and hot alignment specification charts are produced by a cold alignment specification module 60 and a hot alignment specification module 59, respectively. In conjunction with the cold alignment specification module 60 and the hot alignment specification module 59, a select chart type module 57 allows the engineer program 11 to produce a partial alignment, a full alignment, or allow any machine within a machinery unit to be designated as "held," so that all suggested adjustments are based on holding the designated machine stationary. These alignment options will be described in detail later. Finally, associated with the cold alignment specification module 60 and the hot alignment specification module 59, is a select data module 58. The select data module 58 allows display of recommended reverse indicator readings only, recommended angularity and off set values only, both indicator readings and tolerances (described in terms of angularity and off set), and desired angularity and off set values and tolerances.

Lost job module 60' may be included in the engineer program 11.

Next, as shown in Figure 4, an engineering assistance module 61 provides for data entry and data processing to develop the thermal and dynamic machinery factors needed to produce hot and cold alignment specification values. The engineering assistance module 61 includes a thermal growth module 62, a journal movement module 63, a coupling length module 64, an overhung rotor module 65, an optical target conversion module 66, and an uneven bearings module 67. Each of these engineering assistance modules will be described in detail later. Finally, the engineering assistance module 61 may incorporate additional assistance modules to account for other dynamic, thermal and environmental factors that may impact cold or hot machinery alignments.

Figure 5 shows the unit log module 51 in more detail. The unit log module 51 includes the following modules: a recall module 71, a make mechanic module 72, an import module 73, an add new unit module 74, a delete existing unit module 75, a duplicate existing unit module 76, a data entry module 77 and an open manager module 79. In addition, the unit log module 51 includes a connection to the information module 52 and an exit function 78. Finally, the unit log module 51 includes a data display and warnings module 80.

The recall module 71 recalls data from the database 40 (see Figure 3) for a particular machinery unit. When the data is recalled, the engineer program 11 switches from the unit log module 51 to the information module 52. As will be described in more detail later, the information module 52 can be used to revise machinery unit data, to recall and display job reports, and hot and cold alignment specification charts, and to switch to other data entry modules. The data for the particular machinery unit may be recalled by selecting an appropriate unit name from a list of unit names displayed on a graphical user interface generated by the unit log module 52.

The make mechanic module 72 is used to create a mechanic file 16_j. The mechanic file 16_; may be made by inserting a floppy disk, for example, into the remote unit 21, selecting a unit name corresponding to a desired machinery unit, and entering a CREATE_MECHANIC command. The database for the selected machinery unit will be recalled from the engineering database 40 and will be transferred to the floppy disk. The floppy disk can then be used in any local unit that includes the mechanic module such as the ICAD™ mechanic module 15. All machine measurements and alignment specifications are resident on the floppy disk and any alignment task can be completed when results from an alignment system such as the ICAD™ system are entered into the engineer program 11.

The import module 73 controls data entry into the remote unit 21. Data may be imported by inserting the floppy disk into the remote unit 21. Alternately, data may be imported by transmission over the signal path 22, for example. Data obtained from local units such as the local unit 24 may then be displayed on the display 47, or printed on the printer/plotter 46. The data may also be used to print job reports and to update the database 40.

The add new unit module 74 provides the mechanism to add a new machinery unit to the database 40. A name is assigned to the new machinery unit by entering the name via a graphical user interface, for example. The engineer program 11 includes a search feature that will determine if the assigned name already exists in the database 40. If the name is already stored in the database 40, the engineer program 11 will issue a warning, which may be displayed on the display screen 47 using a graphical user interface. If the name is not already in the database 40, the engineer program 11 will transition to the information module 52. The delete existing unit module 75 is used to delete an existing machinery unit from the database 40. The machinery unit to be deleted can be identified by entering its name or designation in an appropriate entry in a graphical user interface, for example. The engineer program 11 will search the database 40 to determine if the designated machinery unit exists. If the designated machinery unit does not exist, the engineer program 11 may issue a warning, which may be displayed on a graphical user interface, for example.

The duplicate existing unit module 76 creates a duplicate entry in the database 40. This is convenient when several machinery units have the same components. The machinery unit to be duplicated is identified and designated by entering the name or number for the unit using a graphical user interface, for example. The engineer program 11 will search the database 40 to ensure that the machinery unit to be duplicated exists. If the machinery unit does not exist, the engineer program 11 may issue a warning. If the machinery unit to be duplicated does exist, the engineer program 11 will create a new entry in the database 40 and will transition to the information module 52, where data may be entered for the duplicated machinery units.

The data display and warning module 80 allows the data in the database 40 to be sorted according to certain criteria. The data display and warnings module 80 also provides warnings to ensure data is entered properly and that the alignment system calculations are performed correctly.

Figure 6 shows the information module 52. The information module 52 serves as a data input module for basic information related to a machinery unit. A mandatory information module 82 receives, processes and displays machinery unit information that is required to complete the alignment specification calculations. Such information may include the number of machines in the machinery unit. If no entry is made, the information module 52 may use a default value. Such a default value may be two machines, for example. The number of machines, once entered, may become a fixed value, which cannot later be changed. Other mandatory information may include designation of a machine as a gear box, if the machinery unit includes such a gear box. Identifying a machine as a gear box informs the engineer program 11 that the machine has two shafts, and allows for different entries for thermal growth and dynamic movements for each of the two shafts.

In Figure 6, an optional information module 83 provides for input, processing and display of other information related to machines in the machinery unit. Optional information includes driver horsepower, maximum RPM of any machine, and other information that can be used to identify the machinery unit.

When the engineer program 11 and the manager program 12 are both loaded into the remote unit 21, the information module 52 may also include a load factor module 83. The load factor indicates the amount of misalignment of machines in a machinery unit. The load factor will be described in detail later.

The information module 52 also includes an enter or modify measurements feature, a review last job feature, a finished-save record to log feature, a return to log without saving feature, and a view cold chart and a view hot chart feature.

Figure 7 shows the machinery lengths module 54. A measurement units module 84 provides for measurements in either the English or metric systems. A power transfer module 85 provides the power transferred at each coupling of the machinery unit. Finally, a longitudinal lengths module 86 provides the distances between the machines. The machinery lengths may be entered for the distance between front, middle and rear support feet hold-down bolt center lines, the distance from support feet hold-down bolt center lines to shaft ends, or coupling pivot points, and the distance between shaft ends or coupling pivot points. As data is entered using the longitudinal lengths module 86 and the power transfer module 85, the data for the specific machinery unit is updated in the database 40.

Figure 8 shows a logical block diagram of the vertical change module 55. The vertical change module 55 includes a thermal growth module 90, a journal movement module 91, and a gear box movement module 92. The thermal growth module 90 computes an value of thermal growth for each machine. The thermal growth value may be based on an estimate of expected temperature rise for a machine from ambient temperature to normal operating temperature. The thermal growth value may also be computed based on actual temperature readings. When it operates, the vertical change module 55 will automatically correct any initial estimations of the expected thermal growth.

The journal movement module 91 provides an input for displacement of the shaft in its bearing housing due to bearing clearances between the bearing surface and the shaft surface. That is, as a shaft rotates, the shaft will tend to "climb" up the bearing surface in a direction opposite to the direction of rotation of the shaft. The amount of "climb" depends on the bearing and the bearing clearances, but is typically 1/3 of the way up the bearing wall. The journal movement, or rotor climb, is needed to compute the dynamic part of the alignment. The journal movement module 91 uses bearing clearances for sleeve-type bearings, for example.

The gear box movement module 92 provides an input for gear movements, where a gear arrangement is included as a machine in a machinery unit. In a typical gear box, a high speed shaft and a low speed shaft may be coupled through a reduction gear arrangement. In such a gear box, the two shafts commonly experience different amounts of movement due to gear forces developed during machinery operation. Thus, a separate entry may be made for each shaft.

Figure 9 is a logical block diagram of the horizontal change module 56. The horizontal change module 56 includes a thermal growth module 95. The thermal growth module 95 computes expected growth in the casing (the supporting metal beneath the shaft of the machinery unit) of a machine as the machine heats up from non-operating, ambient conditions, to operating, hot conditions. Such thermal growth can cause displacement (angular and off set) of the machine's shaft from the cold, static position of the shaft. For most machines, the thermal growth in the horizontal plane is expected to be zero. However, gear boxes may experience horizontal thermal growth for the "non-pinned" shaft in the gear box. Since the high speed shaft is normally "pinned", all thermal growth will affect only the low speed shaft.

Also shown in Figure 9 is a journal movement module 96. Operation of the journal movement module 96 is similar to that of the journal movement module 91 shown in Figure 8.

Finally, the horizontal changes module 56 includes a gear box movement module 97. The gear box movement module 97 operates in a manner similar to that of the gear box movement module 92 shown in Figure 8.

After an alignment check (hot or cold) is performed on a machinery unit, one or more of the machines may require movement in order to place the machinery unit into optimum alignment. However, movement of a particular machine may be undesirable or impossible. For example, movement of a machine may require expensive removal and reinstallation of interfering items such as piping runs. Movement of some machines may create unwanted piping stresses in critical piping systems. Other machines may be bolt bound. The chart type module 57, illustrated in Figure 10 as a logical block diagram, produces suggested movement values based on different alignment options. A partial alignment module 180 produces alignment results (movement values) for any two adjacent machines. Either of the two machines may be held stationary ("held") while the other machine is adjusted. The held machine has its shaft centerline positioned along an imaginary zero axis, and the shaft centerline of the other machine is displayed in its desired misaligned position. This adjustment will be described in detail with respect to the mechanic programs 15.

A full alignment module 181 computes and displays the shaft centerlines of all machines in their desired positions, relative to their operating positions. For example, if thermal growth would raise the shaft center line of a machine into a position having no misalignment, the full alignment module 181 will display the same shaft center line as misaligned low, when displaying a cold alignment situation. A set all units to unit # module 182 allows any machine of a machinery unit to be designated as held. The held machine has its shaft center line positioned on the zero reference line, and all other shaft center lines are positioned in their relative desired misaligned condition. The set all units to unit # module gives the operator optional alignments from which to choose, based on fixing the position of each machine in the machinery unit.

The suggested movements may be based on a number of different alignment check procedures. For example, the suggested movements may be based on the reverse indicator reading method for performing an alignment check. Figure 11 is a logical block diagram of the select data module 58. A recommended readings module 184 provides recommended dial indicator readings when a rim and rim alignment system is used to measure misalignment (i.e., the reverse indicator method). An angularity and off set (A&O/S) module 185 computes the alignment values when the desired values for angularity and off set are used. A readings, A&O/S, and tolerances module 186 provides recommended readings to be taken by the reverse indicator method, and displays tolerances in terms of angularity and off set. Finally, an A&O/S and tolerances module 187 computes the alignment values when the desired angularity and off set values and the tolerances are used.

The select chart type module 57 and the select data module 58 are both used to construct a set of alignment values, or suggested movements to bring the machines into alignment. The suggested movements may be displayed using hot and cold alignment charts. Figure 12 shows a logical block diagram of the cold alignment specification module 60. Included are a horizontal alignment module 190 and a vertical alignment module 191. The horizontal and vertical alignment modules 190 and 191 may display relative alignment for the cold static condition of a machinery unit. That is, the alignment values reflect the thermal growth and dynamic movement that occur when the machines are operating under their normal operating conditions. Because some thermal growth and dynamic movement are expected, the cold alignment values will generally show an off set and angularity value for one or more of the machines.

Figure 13 is a logical block diagram of the hot alignment specification module 59. Included are a vertical alignment module 194 and a horizontal alignment module 195. The hot alignment module 58 includes the effects of thermal growth. For example, the alignment module 58 includes compensations for the movements (thermal growth) that occur when the machines go from a cold, static condition to a hot, operating condition. The hot alignment values should differ from the cold alignment values by the estimated or empirically derived thermal growth factor. The dynamic movement factors may not be included in the hot alignment values if the hot alignment check is conducted with the machines hot, but shutdown and static.

Figure 14 is a logical block diagram of the last job module 60', which includes a vertical alignment module 197 and a horizontal alignment module 198. The vertical and horizontal alignment modules 197 and 198 produce alignment values based on final misalignment values from the most recently completed alignment. The alignment values can be for either a hot or a cold alignment. Since the results of the last alignment are stored in a portion of the engineer data base 40, for example, the last job module 60' can produce the last job alignment values by recalling the data from memory and computing the resulting angularity and off sets for display.

Figure 15 shows the thermal growth module 62. Included are an ambient temperature module 230, a coefficient of expansion module 231, a machinery dimensions module 232, an operating temperature module 233, and a estimated thermal growth module 234. The ambient temperature module 230 provides ambient temperature expected during operation of a machinery unit. The coefficient of expansion module 231 provides the average coefficient of expansion (expressed as inches per inch per degree Fahrenheit when using the English system) for steel or other similar structural members. The machinery dimensions module 232 provides inputs for the distance between the shafts of the machines and the structural supports at which operating temperatures are measured. The operating temperature module 233 provides inputs for temperatures at the machinery support members. The operating temperatures may initially be expected operating temperatures. After an initial alignment, empirical data may be recorded for the machinery supports.

The estimated thermal growth module 234 computes estimated thermal growth for each machine based on the entered ambient temperature, operating temperatures, and machinery dimensions. The estimated thermal growth module 234 will then display values of thermal growth, which will be used in other portions of the mechanic program 15 and the engineer program 11.

Figure 16 is a logical block diagram of the journal movement module 63. The journal movement module 63 includes a diametric clearance module 240 and a direction of rotation module 241. The diametric clearance module 240 provides diametrical clearance for each bearing of a machine. The diametrical clearance equals the bearing inner diameter minus the shaft outer diameter, as is expressed in thousandths of inches. The direction of rotation module 241 indicates whether the shaft rotates clockwise or counter clockwise when looking at the machine on the right of the machinery unit toward the left-most machine. The journal movement module 63 then computes expected journal movement in the horizontal and vertical planes. The journal movements may then be used by the engineer program 11 or the mechanic program 15'. The journal movement module 63 also displays the expected horizontal and vertical plane journal movements.

Figure 17 is a logical block diagram of the coupling length module 64. Included are a coupling dimension module 245, a machinery dimension module 246, and a load factor module 247. The coupling distance module 245 receives different coupling lengths to determine the severity of misalignment that will exist during a cold startup period. To great a misalignment would encourage installation of a longer coupling. A small misalignment would suggest installing a shorter coupling. The machinery dimensions module 246 provides distances between machinery support members and distances from machinery support members to coupling pivot points. The load factor module 247 computes a potential load factor based on the coupling dimensions and the machinery dimensions. Alternately, the potential load factor computation may be completed in the mechanic program 15'. Computation of the potential load factor will be described in more detail later.

Figure 18 is a logical block diagram of the optical target module 66. Included are a target data module 250, a machinery data module 251, and a conversion module 252. Optical alignment instrumentation is sometimes used for alignment purposes and, more often used to accomplish a hot alignment check for a machine. Optical instrumentation may include designation of targets and use of a transit to determine misalignment. The optical target conversion module 66 allows use of data taken from such an optical alignment system and the conversion data module 252 converts the optical readings to values of angularity and off set.

Many machines, such as aeroderivative gas turbines, fans and compressors, have overhung rotors where a large mass of the rotating component sits outboard the machine's bearings. Because these machines not only have journal-type bearings, the mass of the rotor which is beyond or outboard of the journal bearings may cause the rotor to assume a tilted position when the machine is static. The portion of the shaft nearest the outboard mass settles against the bottom of the journal bearing at that end, while the portion of the shaft farthest from the outboard mass settles against the top of the bearing at that end. Thus, the shaft assumes a static tilt when it is not in operation.

Figure 19 is a logical block diagram of the overhung rotor module 65 that is used to compensate for overhung rotors. The overhung rotor module 65 is able to calculate the effects that tilt will have on alignment readings. These effects are then used by the engineer program 11 or the mechanic program 15' to compensate for overhung rotor during any alignment procedure. The overhung rotor module 65 includes a machinery data module 254. The machinery data module 254 provides inputs for machinery dimensions including distances between machinery supports, distances between journal bearings, and distances between journal bearings to the end of the overhung rotor. A bearing clearances module 255 provides the diametrical clearance between the outer diameter of the shaft and the inner diameter of the journal bearing. A compute vertical and horizontal angularity and off set module 256 computes values of angularity and off set based on the entered machinery data and bearing clearances.

As with overhung rotors, a single rotor that has bearings with different diametrical clearances at each end of the rotor can also produce a static tilt. Figure 20 is a logical block diagram of the uneven bearings module 67. Included is a machinery data module 260, a bearing clearance module 261 and a compute tilt module 262. The machinery data module 260 and the bearing clearance module 261 are similar to the corresponding modules described with respect to Figure 19. The compute tilt module 262, similarly produces vertical and horizontal angularity and off set values based on the machinery dimensions and bearing clearances. The values of angularity and off set may then be used in the engineer program 11 and the mechanic program 15'.

The manager program 12 is used to assist maintenance planners in scheduling maintenance and preventative maintenance tasks, preparation of financial reports and preparation of machinery trend logs. The scheduling function of the manager program 12 considers both maintenance and preventative maintenance tasks and use data electronically imported from the engineer program 11 to determine the most cost effective scheduling of tasks. A primary consideration is the development of accurate alignment specifications. The actual required alignment specification will not be known for a machinery unit until a hot alignment specification check has been completed to account for actual thermal growth and static and dynamic movements are accounted for. Figure 21 is a logical block diagram of the manager program 12. The manager program 12 includes a show details module 270, a warnings module 271, and a data display module 272. The show details module 270 may include data related to the machinery unit identification, priority to place on maintenance of the machinery unit, number of machines in a machinery unit, the data of the last job or alignment check, the computed load factor, the type of the last job, and the potential or representative energy cost associated with the potential load factor, for example. The warnings module 271 can produce visual warnings when a particular machinery unit is indicated to be out of alignment, for example. The display data module 272 displays the contents of the engineer program database 40 for selected machinery unit.

Figure 22 is a block diagram of the mechanic program 15'. The function of the modules shown in Figure 22 generally correspond to those shown in Figure 4. The mechanic program 15' also includes a compute movements module 277. The compute movements module 277 calculates suggested movements to adjust one or more machines to bring the machinery unit into alignment. The function of the compute movements module 277 will be described in detail later.

Figure 23 is a block diagram of an embodiment of the local unit 24. Shown connected to the local unit 24 are a measuring device 26. The measuring device 26 is coupled to the local unit 24 via signal path 25, which may be a RS-232 cable and connector, for example. Also shown coupled to the local unit 24 is a printer 280, a keyboard 281 and a mouse 282. The printer 280 may be used to printout reports and alignment check charts from the local unit 24. The mouse 282 and keyboard 281 may be used to enter data into the local unit 24.

The local unit 24 includes a display section 285. The display section 285 may be a liquid crystal display or similar device. The display section 285 may display a data window 287 and a soft keyboard 286, for example, depending on operation of software in the local unit 24. The local unit 24 includes a mechanic database 41. The database 41 stores machinery data and alignment check data related to specific machinery units. An input/output (I/O) 22' is used to import data directly into the local unit 24. The I/O 22' may be a floppy disk drive, for example. An interface 49 may be used to download data from a remote unit or from another location. The interface 49 may connect the local unit 24 to the PSTN or the Internet, for example. A program memory 288 stores operating programs for operating the mechanic program 15' (and the engineer program 11 and the manager program 12, if installed). Finally, a CPU 290 controls operation of the local unit 24 and associated peripheral devices. As described above, the local unit 24 may be embodied in a personal computer such as a lap top computer.

Figure 24 shows another embodiment of a local unit 24'. The local unit 24' shown in Figure 24 is much simpler than the local unit 24 shown in Figure 23. In Figure 24, the local unit 24' may include a processor 291, indicators 293, a mechanic database 292, and the I/O 22'. The indicators 293 may provide a go, no go indication that data has been correctly stored in the mechanic database 292. The processor 291 controls operation of the mechanic program 15' as well as downloading data to the mechanic database 292. The measurement device 26 may connect to the local unit 24' via a RS-232 connection and signal path 25. Data and other information may be downloaded from a remote site to the local unit 24' via the signal path 22. Similarly, data may be transferred from the local unit 24' to the remote site over the signal path.

Figures 25(a) and 25(b) show an example of an ICAD™ 300. Although illustrated simply, the ICAD™ 300 may be a flexible coupling, or any other coupling used to couple two rotating machines. The ICAD™ 300 comprises a cylindrical center section 310 and end flanges 315 and 316. In the end flanges 315 and 316 are milled passages 320. At least three, approximately evenly-spaced, passages may be provided in the flanges 315 and 316. In other configurations, the flanges 315 and 316 may have four passages or more, spaced approximately evenly around the circumference of the flanges 315 and 316. The passages 320 have a greater diameter at one end than at the other end so as to create a shoulder 321. The shoulder 321 is used to seat a direct-reading measurement device such as an electronic depth indicator or a dial indicator (not shown). Also included in each of the passages 320 is a key way 322 that accepts a corresponding key on the direct-reading measurement device so that the direct-reading measurement device may be installed in only one orientation. When an alignment check is to be performed on machinery units employing the ICAD™ 300, the machines are stopped and a direct-reading measurement device is installed sequentially in the passages 320. The direct-reading measurement device provides a reading that is a measure of the misalignment of the ICAD™ 300 relative to the machines to which it is coupled.

Various measurement holes or notches may be keyed differently or drilled to different depths to differentiate among each other. For instance, by drilling the wider base part of three holes to three different depths that are considerably greater than expected differences in measured distance, the holes can be automatically identified on the basis of the measurements. As an example, if the expected range of measured distance differences is on the order of ten thousandths of an inch, then by drilling the bases of the holes to zero, one-hundred thousandths of an inch and two-hundred thousandths of an inch, then measurement results of 22, 84, and 231 (all in thousandths of an inch) respectively correspond to the shallowest hole, the middle depth hole, and the deepest hole. Various other ways of minimizing the possibility of human error are possible by varying the physical attributes of the measurement locations.

Because the machines are stopped, the alignment check cannot measure actual dynamic movements associated with operation of the machines. However, because the measurements may be taken almost immediately after stopping the machines, the readings will still reflect any thermal growth experienced by the machines as a result of their operation.

Figure 26 shows an embodiment of the EZ-Line™ alignment measuring device 350. In Figure 26, a center unit 352 is disposed between machinery coupling flanges 352 and 354. The center unit 351 may be fixed or may be adjustable in length. Ends of the center unit 352 sit in conical depressions 322 and 324 that exist in the center of the flanges 352 and 354. Attached to the center unit 352 are arms 356 and 358. The arms 358 and 356 extend radially outward and include passages 359 through which a direct reading instrument 360 may be placed. The direct reading instrument 360 may be an electronic depth measuring device with an electronic level (not shown) or may be a conventional dial indicator. The probe end of the measuring device 360 contacts the flange face at points adjacent to the outer circumference of the flange face.

To take misalignment readings, the EZ-Line™ device is rotated so that the measuring device contacts the flange faces at points spaced approximately 90° apart along the circumference of the flanges 352 and 354. The depth indication measurements taken can then be used with mechanic program 15 or the engineer program 11 to develop cold alignment check values.

Figure 27 illustrates the computation of torque vectors that may then be used to compute potential load factors. As stated before, the potential load factor may provide a relative indication of misalignment of coupled, rotating machines. In Figure 27, a reference line 400 represents an ideal position for alignment of a machinery unit 410. A first (driving) shaft 500 is shown inclined with respect to the line 400 such that a centerline 501 forms an angle θ with respect to the line 400. A torque vector 502 lies on the centerline 501, and represents the direction and magnitude of torque produced by a machine that rotates the shaft 500 in the clockwise direction. As a result of the angular displacement between the centerline 501 and the line 400, a torque vector T_R1 530 operates perpendicular to the line 400. The torque vector T_R, 530 is representative of a measure of power that is not available to drive other machinery in the machinery unit 410. A coupling 510, which may be an ICAD™, for example, rotates with its centerline 511 aligned with the line 400. A torque vector 512 indicates transmission of torque from the first shaft 500.

A second (driven) shaft 520 is shown with a centerline 521 displaced angularly from the line 400 at an angle φ. As a result, a torque vector 522, which represent the torque available to drive the second shaft 520 is shown displaced from the torque vector 512 by the same angle φ. A resulting torque vector T_R2540 operates perpendicular to the line 400. The torque vector T_R2540 represents an amount of power that is not available to drive the second shaft 520. The total "lost torque" T_τ is then: f T ⁼ Rl ⁺ ^ R2

The potential lost torque T_τ is representative of a measure of the misalignment of the machinery unit 410. The potential lost torque T_τ may result in wasted energy and may cause damage to either of the machines or the coupling. The potential lost torque T_τ may also cause vibration that may be transmitted to other components coupled to the machines.

Once the potential lost torque T_τ is known, a potential load factor may be computed for each machinery unit. In effect, the potential lost torque is the potential load factor. The potential load factor is another way of expressing misalignment. For most rotating equipment, standard values exist for a maximum allowable misalignment. This maximum allowable misalignment may be 0.5 thousandths of an inch off get at the transmission points per inch of coupling length, for example. If the first shaft 500 generates a torque of 100 ft-lbs., then the maximum allowable load factor would be 1.414 ft-lbs. This maximum allowable potential load factor may then be compared with a load factor computed using the torque vectors. The computed potential load factor is the vector sum of the torque vectors that are not available to drive the shaft. In other word, the potential load factor is simply T_τ. If the value of T_τ exceed the maximum allowable, a realignment of the machinery unit group may be warranted.

Figure 28 is a flow chart showing one operation of the engineer program 11. The process starts at block 900. In block 910, the unit log is displayed and the operator is allowed to choose to recall a machinery unit. If the processor receives a recall command, the process moves to block 920. Otherwise, the process remains at block 910. If the process remains at block 910, then the processor may be commanded to cerate a new machinery unit (block 911) or duplicate and existing machinery unit.

In block 920, an operator may decide to make a mechanic file using part of the database 40. If the operator decides to make a mechanic file, the process moves to block 925. In block 925, the processor may receive an indication that a floppy disk has been inserted in disk drive 22, and may receive a copy command. The processor proceeds to copy the selected data from the database 40 and write the data to the floppy disk.

In block 920, if the processor does not receive the make mechanic command, the process remains at block 920 until the processor receives a signal to display an information screen. When the processor receives the command, the process moves to block 930.

In block 930, the processor displays the information screen. The process then moves to block 935. In block 935, the processor may receive a command to change data in the database 40, and the process moves to block 936. In block 936, the processor receives the new data and writes the new data to the appropriate storage location in the database 40. The process then moves to block 940.

In block 935, if the processor does not receive a change data command, the process moves to block 940. In block 940, the processor receives a select chart command. The process then moves to block 942. In block 942, the processor receives a display data selection. The process then moves to block 944. In block 944, the processor displays the desired alignment chart. The process then ri oves to block 948 and ends.

Operation of a portion of the manager program 12 will be explained with reference to Figure 29. The process starts in block 950. In block 952, the processor displays a unit log screen and awaits an input from an operator. In block 954, the processor receives an import command to import data from the database 40 by way of the engineer program 11. In this example, the import command may be to import data for all machinery units requiring a cold or hot alignment check or an alignment. The processor accesses the database 40 to determine which machinery units have values of angularity and off set that exceed either the hot or the cold alignment check specifications. The processor may also access any machinery unit in the database 40 that has not had a hot or cold alignment check performed within a periodic basis, for example within the last 3 months. The process then moves to block 956. In block 956, the processor displays the data in the unit log for all machinery units identified by the import command. The process then moves to block 958.

In block 958, the processor receives a sort command to sort the displayed data by priority of required action. In this case the required action may be to perform a cold or hot alignment check or an alignment. The processor uses an algorithm to determine priority based on which of the machinery units may be furthest out of specification with respect to either the hot or the cold alignment check specifications or which may have the longest time elapsed since a required periodic hot or cold - alignment check. The machinery unit that has values of angularity and off set that exceed the hot or cold alignment check specifications may be given higher priority than one which has not had the required periodic hot or cold alignment check performed. In block 958, other sort criteria can be established that the processor uses to sort the listed machinery units. Examples of additional sort criteria are load factor, potential energy cost, number of machines in a machinery unit and other criteria. The process then moves to block 960. In block 960, the processor displays the machinery unit data in the unit log according to the specified sort criteria. The process then moves to block 962 and ends.

In addition to the process described above, the manager program 12 may carry out additional data sorting display and computation routines in accordance with its basic program structure as indicated in Figure 21 and the GUIs shown in Figures 61- 63.

As noted above, the method and system of the present invention ultimately calculates movement values needed to bring a train of machines into alignment. The method can be implemented on a variety of systems or hardware platforms. Preferably, a graphical user interface is used.

The method may begin with various forms of input data. In one form, the input data are direct field results obtained with alignment measurement devices, such as commercially available "alignment computers," which may be based on laser or indicator measurements. Such results may be expressed in terms of angularity and off set, as described below. In another form, the input data are direct field measurements taken using the EZ-LINE (TM) or ICAD (TM) (integrated coupling and alignment device) devices available from the assignee of the present invention. Typically, these devices measure distances from which physical locations of machine parts in relation to another machine with respect to relative alignment or misalignment can be quantitatively determined. Also, direct field measurements taken using the "reverse" method may constitute the input data. Alternatively, the input data may be the physical locations of machine parts just described. The input data may be accessed from a database of machinery data. The input data may include, for example, the effects of thermal growth and dynamic factors, such as journal movement, static tilt, and/or gear clearance. If not already included, these effects may be factored into the data before beginning. The data relating to these effects may be empirical or analytically estimated. In the case where the input data are direct field measurements obtained with alignment measuring devices, the field measurements are used to derive relative physical locations of machine parts. Techniques for deriving relative physical locations of machine parts from field measurements obtained with alignment measuring devices are described in detail later in this document. The pertinent machine parts are adjustment points on the machines. For example, the bottom feet of a machine may be vertical adjustment points, where adjustments may be made by shimming under the feet. Similarly, machine parts that serve as horizontal adjustment points exist.

The outputs of the method of the present invention are movement values that, when applied to the adjustment points, would bring the train of machines into a desired alignment configuration. Typically, the desired alignment configuration is approximately perfect relative alignment.

In conceptual terms, the processing of the present invention begins by noting the relative physical locations of pertinent machine parts as points in a three dimensional coordinate system. If the machines are perfectly aligned, the points would coincide on a straight line. If the machines are misaligned, the points will be non-collinear. The present invention contemplates techniques for displacing the points so as to cause them to be collinear. A preferred technique for accomplishing this goal is to first define a straight reference line in the coordinate system. Given a reference line, a set of displacement vectors is calculated so as to move each point onto the reference line. When the corresponding machine parts are moved in accordance with the displacement vectors, the machines are brought into alignment.

In a preferred embodiment of the method, the three dimensional alignment problem is decomposed into two independent two-dimensional alignment problems. In other words, the alignment problem is solved in two planes, one at a time. First, the relative physical locations of pertinent machine parts are resolved into orthogonal components. Preferably, the orthogonal components are along a vertical plane and a horizontal plane. One axis of each plane is generally directed along the same direction as the drive shafts of the machine train, and adjustments to the points are made perpendicular to this axis. Because the planes are orthogonal, adjustments can be made in one plane without effect in the other.

Figure 30 illustrates what has just been described in conceptual terms. Figure 30(a) is a side perspective of a machine train of five rotating machines 1001-1005. Four couplings 1011-1014 couple rotating machines 1001-1005 piecewise. Each machine is illustrated with several bottom feet 1021-1032, which serve as vertical adjustment points. For example, the first machine 1001 has a front foot 1021 and a rear foot 1022; the second machine 1002 has a front foot 1023, a rear foot 1026, and two intermediate feet 1024 and 1025. Each machine contains a rotating shaft that terminates at one or two coupling faces. For example, a coupling face 1041 of the first machine 1001 is directed in the general direction of a coupling face 1042 of the second machine and linked to the coupling face 1042 of the second machine by the coupling 1011. Though the invention is illustrated and described with reference to "coupling faces," the invention works equally as well with any surface of the machine that is perpendicular to the axis of rotation. For example, a shaft end of a machine may be used rather than a coupling face.

Gross vertical misalignment of the machines 1001-1005 is depicted in Figure 30 to better illustrate the operation of the present invention. In reality, the degree of misalignment, even if severe, may be undetectable to the human eye. The first machine 1001 and the second machine 1002, as illustrated in Figure 30(a), are vertically off set but have parallel internal shafts. On the other hand, the coupling face 1043 of the second machine 1002 and the coupling face 1044 of the third machine 1003 are not vertically off set with respect to each other but have internal shafts that are not parallel. The first machine 1001 and the second machine 1002 have relative off set misalignment but not angularity misalignment. The second machine 1002 and the third machine 1003 have relative angularity misalignment but no off set misalignment. As can be seen from the figure, the other coupled machine pairs have both off set and angularity misalignment to varying degrees.

Figure 30(b) is a representation of Figure 30(a) in a vertical plane. In Figure 30(b) the ordinate axis 1051 is directed in the same general direction as the shaft train in Figure 30(a). The abscissa axis 1052 is directed in the same general direction in which the machines 1001-1005 are adjustable at adjustable feet 1021-1032. Points 1061-1072 represent the "locations" of the adjustable feet 1021-1032 in the sense of relative alignment. In particular, the first coordinates of the points 1061-1072 correspond to the locations of adjustable feet 1021-1032 along the same general direction as the shaft train. The second coordinates of the points 1061-1072 correspond to the vertical orientation of the machine shafts sampled at the positions of the adjustable feet 1021-1032. This relationship is illustrated in Figure 30 for the fifth machine 1005.

Figure 31 is analogous to Figure 30 but depicts horizontal alignment rather than vertical alignment. Figure 31(a) is a top perspective of the machines 1001-1005. The machines 1001-1005 are horizontally adjustable at horizontal adjustment points 1081-1092. Figure 31(b) is a representation of the horizontal alignment of the shafts of machines 1001-1005. The points 1101-1112 represent the horizontal adjustment points 1081-1092 in relative alignment "locations" with respect to each other.

Figure 32 graphically illustrates reference lines and movement values. Figure 32(a) is the same vertical plane diagram as Figure 30(b). Figure 32(b) is the same horizontal plane diagram as Figure 31(b) with a different scale. In the vertical plane of Figure 32(a), a vertical plane reference line 1120, in this instance, is shown as being the same as the ordinate axis 1051. An equation for the vertical plane reference line 1120 is y_v = 0. In the horizontal plane of Figure 32(b), a horizontal plane reference line 1130 is illustrated. The horizontal plane reference line 1130 may be generally characterized by the standard linear equation y_h (x_h)= m_hx_h + b_h where m_h is the slope of the line and b_h is the y-intercept. Note that the vertical plane reference line 1120 may be said to have parameters π , = b_v = 0. Various techniques for choosing m_h , b_h , m., and b_v are described later.

For now, given parameters of the vertical plane reference line 1120, vertical movement values are calculated as differences in abscissa values from points 1061- 1072 and the vertical plane reference line 1120. Because the vertical plane reference line 1120, in this instance, is everywhere zero, the vertical movement values in this case are simply the additive inverses (i.e., multiply by -1) of the second coordinates of the points 1061-1072. For example, if the point 1064 has coordinates (x_v4,y_V4) = (11.32, 3.20), then the corresponding vertical movement value is vm₄ = -3.2, meaning that the corresponding adjustable foot needs to be lowered by 3.2 units (typically thousandths of an inch) as part of the alignment operation.

The more general case of movement value calculations is illustrated in the horizontal plane of Figure 32(b). As an example, consider the point 1110 and assume its coordinates are given by (x_hιo_>y_hic)- Then the horizontal movement value is calculated according to well understood plane geometry equations as hm₁₀ = y_hl0 - y_h

(^Xhl0 ) ⁼ YhlO ~ ^mh^Xhl0 ^" h-

Next will be described various techniques for defining a reference line. In general, a line may be defined by two points. Thus, it is possible to define a reference line by choosing two points, such as the two (adjustment) points 1061 and 1062 shown in Figure 32(a). When a particular point is chosen to define the reference line, then the resulting movement value for the adjustment point corresponding to that particular point will be zero. Thus, according to the present invention, points where adjustment is impossible or least desirable can be isolated and not adjusted while still accomplishing alignment. Possible reasons for not being capable or desirable to adjust a point include "bolt bound" conditions and pipe strain. A bolt bound condition is one in which further horizontal adjustment is constrained because bolts fastening the machine to the floor permit only a limited range of movement. Pipe strain refers to a condition in which further adjustment to a machine would strain a physical interface to the machine.

When two points of the same machine are chosen to define the reference line, then that machine will not be adjusted at all. This has the effect of using that machine as the reference to which all other machines are aligned. This is the case in Figure 32(a), where the first machine 1001 is held still while the other machines 1002-1005 are moved into relative alignment with the first machine 1001.

Another possibility for defining a reference line is to calculate its parameters using linear regression or linear curve fitting, which are generally well known. One such curve fitting technique is linear least squares, which produces a straight line that "best" fits the points in the sense that it minimizes a metric defined as the sum of the squared second coordinate differences from the points to the resulting line. Other "best" fits can be obtained by minimizing other metrics, such as the maximum second coordinate difference (i.e., "mini-max"), as is also well known. It is possible to perform linear regression or curve fitting on the basis of less than all of the points, by ignoring some points that are less sensitive to extreme movement ranges.

Those skilled in the art will also readily appreciate that linear regression or linear curve fitting techniques can be utilized with constraints. For example, if one or more points are bolt bound and cannot be adjusted further in one direction, then a best fit that minimizes the chosen metric without violating the constraints can be found, utilizing well known techniques of constrained optimization.

An overall method of the present invention is illustrated in the flow chart of Figure 33. The method begins by calculating point coordinates, such as points 1061- 1072 or 1101-1112, as depicted in block 1200. Next, a reference line is defined according, for example, to one of the aforementioned techniques, as depicted in block 1210. Then, a set of movement values are calculated as described previously, as depicted in block 1220. The points and reference line and possibly other information such as calculated movement values may be displayed, as shown in block 1230. A human user might examine the results and determine if the results are acceptable, as shown in block 1240. Alternatively or additionally, an automatic check of possibly unacceptable conditions, such as bolt bound or pipe strain conditions, may be performed as part of the processing illustrated in block 1240. In a more sophisticated embodiment, expert systems and/or artificial intelligence techniques may be employed to make the decision in block 1240 and adaptively continue if unacceptable. If the results are unacceptable, a new reference line is determined and blocks 1210-1240 are repeated. If the results are acceptable, the adjustments to the machines may be made, as shown in block 1250.

One skilled in the art will appreciate that many variations are possible for the processing depicted in the flowchart of Figure 33. For example, not all steps need be performed. In particular, the step depicted in block 1200 may be bypassed if the method begins with a given set of points. The step depicted in block 1250 also need not be performed. Also, variation in the order of the steps is possible. In particular, the order of the steps illustrated by blocks 1220 and 1230 is arbitrary. Steps may be performed simultaneously rather than the sequential approach illustrated in the flowchart. Finally, additional unillustrated steps, such as recording the final movement values, may be performed. Other variations to the processing illustrated in Figure 33 are possible, as one skilled in the art would appreciate.

A block diagram of computer hardware of the present invention is illustrated in Figure 34. Input data in the form of machine data from a database, measurement data from the field, and/or point coordinates directly are received by a data input device 1300. The input device 1300 may be a keyboard, point and click device (e.g., mouse), touch screen, modem, data port, light signal input, or something similar. The data received by the data input device 1300 is stored in a data memory 1310, where it is accessed by a processor 1320. The processor 1320 is preferably a general purpose microprocessor that executes program instructions stored in the program memory 1330. The program memory 1330 may be physically packaged together or separately from the processor 1320. The program memory 1330 may be a computer readable storage device, such as a disk, tape or memory chip. The program instructions direct the processor 1320 to define a reference line and calculate movement values. Final results, intermediate results, and other information generated by the processor 1320 may be displayed on the display 1340. The computer hardware may also include a user input device 1350, by which a user may interact with the program. The user input device 1350 and the data input device 1300 may be the same device or separate devices.

The input device 1300 and the data memory 1310 together perform the function of accessing data. The processor 1320 and the program memory 1330 together perform the function of determining a reference and movement values. Therefore block 1350 is a means for determining a reference and movement values. However, other equivalent structures are possible for the block 1350. For example, the same function may be performed by a hardwired circuit such as an ASIC (application specific integrated circuit), or a firmware programmable device such as a gate array or programmable logic array.

In one embodiment of the present invention, the input data includes historical information about past movements applied to the particular machine train under consideration. The present invention may then analyze the historical data to determine trends or otherwise try to predict future misalignment. With such information, the method of the present invention may perturb the final movement values to compensate for predicted drift. For example, the present method may predict the points 1061-1072 and/or 1101-1112 at the time of the next scheduled alignment check, say three months in the future, compute a set of movement values to align that predicted future configuration, and then average the presently needed movement values with the predicted future configuration values so as to minimize the time averaged misalignment over the next three months. Next will be described methods and devices for measuring alignment data and deriving physical locations or positions of pertinent machine parts. These methods and devices relate specifically to the processing illustrated in block 1200 of Figure 33 and the program instructions, or equivalent functionality, of block 1350 in Figure 34.

Figure 35 depicts an alignment measurement device 1400 situated between a first shaft end 1041 and a second shaft end 1042. The alignment measurement device 1400 depicted in Figure 35 is similar to the EZ-LINE (TM) device available from the assignee of the present invention and described in greater detail in co-pending U.S. Patent Application Serial No. 09/088,093. The alignment measurement device 1400 comprises a main shaft 1401 that is extended to fit between the two shaft ends 1041 and 1042. Extending perpendicularly from the main shaft 1401 are two rigid arms 1404 and 1405. Along each rigid arm is a measurement device such as dial indicators 1408 and 1409, both of which measure a distance to the respective shaft ends. Other electronic or manual distance measuring devices may be used in place of the dial indicators 1408 and/or 1409. The main shaft 1401 is placed between the two shaft ends 1041 and 1042 by means of one or more telescopically extending ends. When compressed, the telescopically extending ends permit the main shaft 1401 to be inserted between the two shaft ends 1041 and 1042. When the telescopically extendable end(s) fully extends, the alignment measuring device 1400 fits snugly between the two shaft ends 1041 and 1042. Each end of the main shaft 1401 may be tapered to fit in the center of the respective shaft end. Alternatively, each end of the main shaft 1401 may be or terminated with a ball, which may be a swivelling ball joint. Preferably, the alignment measuring device 1400 can be rotated easily about the axis of the main shaft 1401 to permit taking distance measurements from the arms 1404 and 1405 to the shaft ends 1041 and 1042, respectively, at any point along the rim of the shaft ends.

Many variations of the alignment measurement device 1400 are possible. Both rigid arms 1404 and 1405 need not be attached to the main shaft 1401 simultaneously. A single rigid arm that can be attached to and detached from each end of the main shaft 1401 may be utilized. Alternatively, a single rigid arm attached anywhere to the main shaft 1401 may be utilized to measure distances to each shaft end or coupling face by providing two oppositely directed distance measuring devices or one reversible distance measuring device, provided accurate distance measurements are possible across the span contemplated. When two rigid arms are present, they need not point in the same direction. In fact, the measurement distances to the first shaft end or coupling face 1041 is independent of the measurement of distances to the second shaft end or coupling face 1042, provided that the planes of measurement (e.g., the planes in which rigid arms 1404 and 1405 rotate) are parallel and separated by a fixed distance.

The alignment measuring device 1400 as depicted in Figure 35 may be utilized to measure alignment or misalignment data in the following manner. First, the alignment of the shaft ends or coupling faces 1041 and 1042 in a first plane, such as the vertical plane, is measured. Second, the alignment of the shaft ends or coupling faces 1041 and 1042 in a second plane, such as the horizontal plane, is measured. The same set of measurements may be utilized to determine alignment in both planes.

To measure alignment in the vertical plane, for example, the device 1400 is first configured as illustrated in Figure 35, viewed as a side perspective, where the rigid arms 1404 and 1405 point in the generally upward direction. In this position, dial indicator measurements are recorded. Then the entire device 1400 is rotated about the axis of the main shaft 1401 so that the rigid arms 1404 and 1405 point generally downward, at which position dial indicator measurements are taken again. With respect to the coupling face 1041, the dial indicator measurement taken in the top position may be denoted x_lτ and the dial indicator measurement read from the bottom position may be denoted x_lB. Likewise with respect to shaft end or coupling face 1042, the top and bottom dial indicator measurements are denoted as x_2T and x_2B respectively. Also, the exact or nearly exact angular direction of the rigid arms 1404 and 1405 is recorded at the points when the top and bottom distance measurements are taken. These angular measurements from the vertical plane are denoted with respect to the first shaft end or coupling face 1041 as β_]T and β_1B respectively, with similar notation used with respect to the other shaft end or coupling face 1042. Finally, note is taken of the radial distance from the center of device 1400 to the point on the rigid arms 1404 and 1405 at which the distance measurements were taken. With respect to the first shaft end or coupling face 1041, these radial distances are denoted r_1T and r_1B at the top and bottom positions respectively, with similar notation used with respect to the other shaft end or coupling face 1042.

The measurements just described are illustrated in Figures 36(a) and 36(b). Figure 36(a) shows a side perspective of a first machine 1001 with a first shaft end or coupling face 1041. From this side perspective, the shaft end or coupling face distance measurements x_1T and x_]B are as illustrated, and the vertical separation between the dial indicator positions is indicated as d,. Figure 36(b) illustrates the dial indicator measurements as viewed facing directly towards the shaft end or coupling face 1041. From this perspective, the angular off sets from the vertical plane are readily apparent as denoted by β_lτ and β_IB. Also, the radial distance from the center of the ridged main shaft 1401 to the dial indicator position is denoted at the point of top measurement as r_!T and at the point of bottom measurement as r_1B . Figure 36(b) illustrates how d,, the vertical separation between the dial indicator positions, is derived. In particular, by using well known trigonometric relationships, the vertical separation between the dial indicator positions is derived as d_t = r_;T |cos(β_lτ)| + r_1B |cos(β_IB)| . When β_lτ ~ β_1B ~ 0, this expression simplifies to d, = r_IT + r_1B . When r_1T ~ r_1B = r, such as when the same rigid arm is rotated around to make both measurements, then this expression simplifies further to d, = 2r.

The relative vertical orientation of the shaft end or coupling face 1041 is illustrated graphically in Figure 37 as a triangle 1420. The hypotenuse of the triangle 1420 represents the shaft end or coupling face 1041, which is shown to be off set in the vertical plane by an angle . The other two sides of the triangle 1420 are d, and x_1T-x_lB, as shown in the figure.

Figure 38 illustrates two machines 1001 and 1002 with two shaft ends or coupling faces 1041 and 1042 in relative misalignment. The measurements d„ x_lτ and x_1B are illustrated with respect to the first shaft end or coupling face 1041 of a first machine 1001 and are as described above in relation to Figures 36 and 37. Likewise, analogous quantities — d₂, x_2T and x_2B — are illustrated with respect to the second shaft end or coupling face 1042 of a second machine 1002. Also illustrated in Figure 38 are horizontal distances between various points of interest, including the center points of each shaft end or coupling face and adjustment feet locations, as denoted by the symbols c, 1_1R, 1_1F, 1_2R and 1_2F.

Next will be described a method for bringing the second shaft end or coupling face 1042 into alignment with the first shaft end or coupling face 1041 while holding the first machine 1001 still. The geometry of this movement and this calculation is illustrated in Figure 39. In Figure 39, the triangle 1420 represents the angularity of the first shaft end or coupling face 1041. Likewise the triangle 1450 represents the angularity of the second shaft end or coupling face 1042. The triangle 1440 represents the off set between the first shaft end or coupling face 1041 and the second shaft end or coupling face 1042. According to Figure 39, bringing the second shaft end or coupling face 1042 into alignment with the first shaft end or coupling face 1041 requires three adjustment that are added together to result in a total adjustment. First, an adjustment to compensate for the angle α representing the off set of the second shaft end or coupling face 1042 from the first shaft end or coupling face 1041 is needed. This first adjustment may be denoted s₀ and is derived by using simple triangular proportions as s₀ = c(x_IT - x_IB)/d,. The adjustment s₀ must be applied to all adjustable feet locations of the second machine 1002. Next, an adjustment to compensate for the angles cc and γ representing the angularity of the first and second shaft ends or coupling faces 1041 and 1042, respectively, is needed. This second adjustment is different for the different adjustable feet of the second machine 1002. This second adjustment applied to the front adjustable foot 1023 of the second machine 1002 is given by

*2F (^X1T ^{" X}1B) '"I + *2F (^X2T ^{" X}2B)' "2' where the first term of this expression corrects for the angularity cc and the second term accounts for the angularity γ. Similar consideration to the rear adjustable foot 1024 yields an adjustment value given by

(1_2F +I₂RX^XIT " ^XIB)^! + (1_2F +l_2R)(x_2T - ^χ2_B) d₂- Thus, the overall correction needed to the front adjustable foot 1023 is s_2F = c(x_1T - XiβVd; + 1_2F [(x_1T - ι_B)/dι + (x_2T - _2Byd₂] and to the rear adjustable foot 1024 is

^S2R ^{= S}2F ^"*^" *2R 1(^X1T ~ ^X1B)'"1 ^"K^X2T ^{" X}2B '"2J-

As an alternative to the preceding calculations, next will be described a method for adjusting each machine 1001 and 1002 at its respective adjustable feet locations so as to bring them into relative alignment. In this technique, each machine is adjusted independently to bring it into alignment with the reference line which runs through the axis of the main shaft 1401 of the device 1400. The geometry of this calculation is illustrated in Figure 40, where two triangles are illustrated. The top or right triangle 1420 is the same triangle as illustrated in Figure 37. The bottom triangles 1430 and 1435 are similar triangles to the triangle 1420, as the angles cc are the same as indicated. Adjustable feet positions 1_1F and 1_1R are indicated on the bottom triangles. Because of the similarity of the triangles, the vertical adjustment or movement values s_IF and s_1R can be described from the measured values d,, x,_τ, x,_B, and 1_IF and 1_1R. In particular, the expressions for s_1F and s_1R are as follows: s_[F= l_IF (x_IT-x_IB)/d, and

S_lR = (l_lF + l_lR) (^Xrr ^X _lByd,. Thus, by shimming under the front adjustable foot 1022 an amount s_1F and by shimming under the rear adjustable foot 1021 an amount s_1R, the shaft end or coupling face 1041 of the first machine 1001 is brought into perfect vertical orientation. Similarly for the second machine 1002, the following expressions for adjustment movement values can be derived:

^S2R ⁼ 2F ^"*^" *2R)(^X2T ^{" X}2B)' "2"

Thus, by shimming under the adjustable 1023 and 1024, by amounts S_2F and S_2R respectively, the second shaft end or coupling face 1042 of the second machine 1002 can be brought into perfect vertical orientation. Overall, the shaft end or coupling face 1041 of the first machine 1001 and the shaft end or coupling face 1042 of the second machine 1002 are brought into relative vertical alignment.

What has just been described is a method for correcting vertical misalignment between two machines. The foregoing method is equally applicable to correction of misalignment in any plane, not just the vertical plane, as one skilled in the art will realize. Typically, the foregoing method should be applied in two perpendicular planes to bring the pair of machines into total alignment. Due to orthogonality, alignment in a first plane is independent of alignment in a second plane perpendicular to the first. Therefore, the preceding method, as described with regard to the vertical plane, can also be utilized to correct for misalignment in the horizontal plane by simply thinking of top as being left and bottom as being right, or vice versa. Graphically, this can be accomplished by viewing Figure 31 as a top perspective rather than a side perspective. The method may be applied in a third plane or more to verify the results from the other planes.

In a preferred embodiment for dual plane alignment, four distances are measured to a machine surface perpendicular to the axis of shaft rotation. When viewed as facing directly towards the shaft ends or coupling face 1041, as shown in Figure 36(b), the dial indicator measurements are preferably taken at β = 0, β = π/2, β = π and β = 3π/2 (i.e., at the twelve o-clock, three o-clock, six o-clock, and nine o- clock positions). The β = 0 and β = π measurements are used for vertical alignment, and the β = π/2 and β = 3π/2 measurements are used for horizontal alignment.

The four distance measurements taken at taken at β = 0, β = π/2, β = π and β = 3 π/2 can be utilized to detect aberration, holes, or warping in the shaft end or coupling face 1041. If the distance measurements at these points are denoted d_I2, d₃, d₆, and dc,, then there is a warp, hole, bump, or other surface aberration if d_I2 + d₆ ≠ ά₃

Alternatively, only three distances measurements may be utilized to calculate misalignment in both planes simultaneously, because three points determine a plane. With reference to Figure 36(a), it is apparent that the horizontal separation between the dial indicator positions is given by d, = r_1T | sin(β_ιτ) | + r_1B | sin(β_1B) | . Just as the cosine function projects the radial vectors into the vertical plane, the sine function projects the radial vectors into the horizontal plane. Therefore, given any two points of measurement about a coupling face or shaft end, those two measurements can be utilized to calculate misalignment in either the horizontal or vertical plane.

To this point, the method of the present invention has been described for relative alignment of two machines capable of being coupled. The foregoing methods can be applied pairwise to adjacent machines in a multi-machine train of arbitrary length. The result of each pairwise analysis is a set of movement values that would align one of the shaft ends or coupling faces of one machine with a generally oppositely directed shaft end or coupling face of the other machine in the pair. The results of these pairwise alignment analyses can be combined to generate compound alignment data. For example, the movement values calculated to align the shaft end or coupling face 1042 of the second machine 1002 to the shaft end or coupling face 1041 of the first machine 1001 will result in a movement of the opposite shaft end or coupling face 1043 of the second machine. By adding this amount to the calculated movement values required to align the shaft end or coupling face 1044 of the third machine 1003 to the shaft end or coupling face 1043 of the second machine 1002, the resulting movement values for the third machine will bring into alignment the first, second, and third machines. One skilled in the art will appreciate that this process can be continued arbitrarily in either direction as far as necessary to achieve global relative alignment along the entire machine train.

Although the preferred technique for obtaining alignment/misalignment data for a train of machines is to do pairwise measurements as just described, it is also possible to take measurements of all machines jointly. For example, one fixed reference can be used with respect to all machines in a train to take relative measurements, such as positions, shaft off set, shaft angularity, etc. Regardless of how the measurements are taken or alignment/misalignment data is otherwise obtained, the methods for computing the movements needed to bring the machines into relative alignment can be performed jointly or pairwise, as described above.

Given a movement value or adjustment value that represent the amount of movement or adjustment needed at a pertinent point on a machine so as to bring the machine into some form of relative alignment, it is a simple matter to reverse the sign of this movement value to describe the present position or location of the machine, relative to an aligned position, such as illustrated in Figures 30-32.

To this point, the method of the present invention has been described for relative alignment of two machines capable of being coupled. The foregoing methods can be applied pairwise to adjacent machines in a multi-machine train of arbitrary length. The result of each pairwise analysis is a set of movement values that would align one of the coupling faces of one machine with a generally oppositely directed coupling face of the other machine in the pair. The results of these pairwise alignment analyses can be combined to generate compound alignment data. For example, the movement values calculated to align the coupling face 1042 of the second machine 1002 to the coupling face 1041 of the first machine 1001 will result in a movement of the opposite coupling face 1043 of the second machine. By adding this amount to the calculated movement values required to align the coupling face 1044 of the third machine 1003 to the coupling face 1043 of the second machine 1002, the resulting movement values for the third machine will bring into alignment the first, second, and third machines. One skilled in the art will appreciate that this process can be continued arbitrarily in either direction as far as necessary to achieve global relative alignment along the entire machine train.

Given a movement value or adjustment value that represent the amount of movement or adjustment needed at a pertinent point on a machine so as to bring the machine into some form of relative alignment, it is a simple matter to reverse the sign of this movement value to describe the present position or location of the machine, relative to an aligned position.

Figures 41-64 show graphical user interfaces (GUIs) that may be used with the system and method of the invention. Not all the GUIs will be available with all the alignment system programs. In addition, the functionality of some of the GUIs may change based on the program in use. In Figure 41, a unit log 1500 includes a data section 1501. The data section 1501 may be used to display information related to specific groups of machines. The data section 1501 may show a unit identification number, the number of rotors in the machine group, a date of the last alignment and other information related to alignment of the machines. A warning section 1502 displays warnings that may pertain to a machine group. For example, the warning section 1502 may provide a warning if critical length measurements or horse power data is not available in the database 40.

A recall existing unit section 1504 allows a user to recall data that pertains to a particular machine group. When the desired machine group is selected, the database for that machine group will be recalled and the operating program will automatically switch to an information screen that can be used to enter and view data.

A make mechanic disk section 1504 allows an operator to select a machine group and to download data from the database 40 for that machine group to a portable storage medium such as a floppy disk, for example. All unit measurements and alignment specifications, both hot and cold are resident on the disk and any alignment task necessary can be completed by entering answers from any alignment system, including the EZ-Line™ and ICAD methods.

A get data from mechanic section 1505 (engineer program 11 only) allows an operator to transfer alignment data and other readings stored on a floppy disk, for example, to the database 40. A create new unit section 1506, delete unit 1507, and duplicate unit 1508 allow an operator to create a new machine unit, delete an existing machine unit, or duplicate an existing machine unit, respectively.

Figure 42 shows the GUI 1500 with entries in the create new unit section 1506, delete unit section 1507 and duplicate unit section 1508.

Figure 43 shows a GUI 1510 for entering data that pertains to a particular machine unit. The GUI 1510 may be accessed directly from the GUI 1500 shown in Figure 41. The GUI 1510 includes a number of sections in which data may be entered. When the data is entered in these sections, the data is automatically written to a memory space corresponding to the identified machine unit.

A maximum rpm of any unit section 1511 is used for entering maximum rpm, which is necessary for the program to compute alignment tolerances. A unit ID section 1512 allows an operator to designate a particular machine unit. A number of rotors section 1513 is a mandatory entry with a default value of 2. A unit name section 1514 allows an operator to use a generic or popular name for each machine in the machine unit. A gear box identification section 1515 is a mandatory entry if a gear box is present in the machine unit. This entry informs the operating program that there are two shafts in this machine and allows for different entries for thermal growth and mechanical movements of each shaft within a gear box. A driver horse power section 1516 to indicate the horse power generated by the driving machine. The GUI 1510 also includes other sections and features that allow an operator to view hot and cold alignment checks, enter and modify entries and display other data.

A machinery lengths GUI 1520 is shown in Figure 44. The machinery lengths GUI 1520 may be accessed from the information GUI 1510. The GUI 1520 allows an operator to designate English or metric measurement units, distances between components of machines and horse power transmission at each coupling. The machinery lengths GUI 1520 shows a machinery unit in a vertical screen orientation.

Figure 45 shows an expected vertical changes GUI 1530. The GUI 1530 allows an operator to select English or metric units and allows an operator to input values of thermal growth and journal movement, or rotor climb in gear box mechanical movement.

Figure 46 shows an expected changes in the horizontal plane GUI 1540. The GUI 1540 allows an operator to select English or metric units. The GUI 1540 also allows an operator to input values of thermal growth, journal movement and high and low speed shaft gear movement for each machine in the machine unit. Note that because the thermal growth at each support put is determined by the temperature change in the supporting metal between the shaft of each unit, except for the gear box thermal movement in the horizontal plane would normally be estimated to be zero. Because a high speed shaft may be assumed to be pinned, the only thermal growth will normally be at the low speed shaft side of the gear box.

Figure 47 shows a hot alignment specification chart GUI 1550. The GUI 1550 includes a horizontal alignment specification chart 1551 and a vertical alignment specification chart 1552. As shown in Figure 47, the horizontal and vertical alignment specification charts show off set and angularity for four machines in a machine unit. Also provided in the GUI 1550 are values of angularity and off set for each machine in the machine unit. Figure 48 shows a cold alignment chart GUI 1560. The GUI 1560 is similar to the GUI 1550 shown in Figure 47. Because machines in a machine unit do not experience thermal growth or dynamic movement, the cold alignment charts will display off set and angularity values that include a compensation for thermal growth, static tilt, gear movement, and rotor climb.

Figure 49 shows a GUI 1570 that allows an operator to select a type of alignment chart to display. Using the GUI 1570, an operator may elect to show a partial alignment, which means alignment of any two adjacent machines, a full alignment with the shaft center line of all machines displayed in their desired position relative to their operating position, a set all units to unit number alignment, which allows an operator to designate any one unit as a held unit, and a use previous entered choice alignment.

Figure 50 shows a GUI 1580 that may be used to select the data to be displayed on an alignment chart. As shown in Figure 50, the GUI 1580 allows an operator to select reverse indicator readings only, show recommended placement only, show both indicator readings and placement with tolerances, and show placement with recommended tolerances. The recommended readings may be displayed on a dial indicator window and the angularity and off set values in a text box.

Figure 51 shows a last job GUI 1590. The GUI 1590 includes vertical and horizontal alignment check charts for the most recently completed alignment check. The alignment charts shown in Figure 51 are produced from the final misalignment values obtained during that most recent alignment check. The alignment charts show the misalignment of each of the components of the machinery unit relative to a desired alignment specification, either cold or hot. For example, if a motor's cold alignment specification calls for it to be set five thousandths low, and the final realignment reading show it to be set four thousandths low, the alignment chart shown in Figure 51 would show the motor to be one thousandths too high, and the final off set would be +0.001". Figure 52 shows a thermal growth help GUI 1600. The thermal growth help GUI 1600 may be used to enter machinery data and other information used to compute thermal growth for a machine. When the machinery dimensions, ambient temperature and operating temperatures are entered, the operating program will compute values of thermal growth to be entered into the mechanic program for computing suggested movements.

Figure 53 shows a journal movement GUI 1610. The journal movement GUI 1610 is used to enter data that is used to compute rotor climb. As shown in Figure 53, an operator may enter bearing diametrical clearance and direction of rotation, and the operating program will compute journal movement in the horizontal and vertical planes.

Figure 54 shows a coupling length GUI 1620. The coupling length GUI 1620 permits an operator to enter different coupling lengths and determine the severity of misalignment during a cold startup period. An operator can enter all information manually, or click on an appropriate unit couple button and all data currently residing in the appropriate memory space of the database 40 will be automatically entered and the coupling length computed. The GUI 1620 allows an operator to vary coupling lengths and determine the effect of varying the coupling length on load factor.

Figure 55 shows an optical target conversion GUI 1630. Optical alignments are sometimes used to attempt to achieve a hot alignment condition. To use the results of the optical alignment procedure, the optical target readings must be converted to values that can be used by the operating program. The optical target conversion GUI 1630 allows an operator to enter readings from optical instruments and the operating program then converts these readings to values of angularity and off set. The values of angularity and off set can then be used by the mechanic program to obtain machinery movement values.

Figures 56-58 show GUIs that may be used to compute static tilt due to overhung rotors. The three conditions illustrated are for a right overhung rotor, a left overhung rotor and both rotors overhung. The operating program calculates the effect of tilt on alignment readings and provisions based on data entered into the overhung rotor GUIs. The result is values of angularity and off set that enable the mechanic program to compensate for overhung rotor or static tilt during any alignment procedure.

Figure 59 shows an uneven bearing clearances GUI 1670. The GUI 1670 performs functions similar to the overhung rotor GUIs. By entering bearing diametrical clearances in the GUI 1670, the operator provides information that the operating program can use to calculate values of angularity and off set. These values of angularity and off set are also used by the mechanic program during any alignment procedure.

Figures 60-62 show a GUI 1700 that is used with the manager program to plan and schedule maintenance tasks and to identify machine units that require alignment. The scheduling function of the manager program considers both maintenance and preventive maintenance tasks and uses data electronically imported from the mechanic program to determine the most cost effective scheduling of tasks. A primary consideration is development of alignment specifications that are accurate. High priority is placed on this task because a severity of misalignment of any machine can only be guessed at until initial placement of a machine and initial cold and hot alignment checks. The required placement (the alignment specification) will not be known until actual thermal growths are known, which requires empirical data from the field.

Figures 63 and 64 depict GUIs according to the present invention, as might be shown on the display 1340. The graphical user interface provides a visual representation of the positions of pertinent machine parts with respect to relative alignment. The points 1901-1906 are depictions of adjustable feet locations. Line segments 1911-1913 connect the points that correspond to the same machine. Typically, the pertinent machine adjustment points are collinear or can be treated as collinear, though that need not be the case. The graphical user interface also provides a visual representation of a reference line 1920. In Figure 63, the reference line 1920 is the same as the second coordinate axis and passes through both feet of the leftmost machine. In Figure 64, the reference line 1920 is sloping downward with respect to the second coordinate axis and passes through points 1902 and 1906. The graphical user interface displays numerical movement values 1931-1936 required to bring each point into relative alignment along the reference line 1920.

A user of the graphical user interface can alter the reference line 1920. One way of altering the reference line 1920 is illustrated in Figures 63 and 64 as input boxes 1941-1942 and input increment/decrement buttons 1943-1946. The value entered in input box 1941, which can be incremented or decremented by buttons 1943 and 1944, respectively, sets the second coordinate or Y axis value of the reference line 1920 at the first point 1901. Likewise, the value entered in input box 1942, which can be incremented or decremented by buttons 1945 and 1946, respectively, sets the second coordinate or Y axis value of the reference line 1920 at the sixth point 1906. Other ways of controlling the reference line 1920 would be apparent to those skilled in the art.

The terms and descriptions used herein are set forth by way of illustration only and are not meant as limitations. Those skilled in the art will recognize that numerous variations are possible within the spirit and scope of the invention as defined in the following claims.

Claims

In The Claims:

1. A system for determining an alignment of coupled, rotating machines, each of the machines having rotor terminating in a rotor flange connected to a coupling, the coupling having a coupling flange corresponding to the rotor flange, the coupling adapted to receive a measuring device at locations spaced radially about an outer portion of the coupling flange, comprising: a measuring device that measures distances between a rotor flange face and a corresponding coupling flange face, the distances measured for each of the machines, the distances measured at least three locations on an outer radial portion of the coupling flange; an interface coupled to the measuring device, the interface receiving the distance measurements; and a processor coupled to the interface that computes a torque vector based on the distance measurements.

2. A system for determining an alignment of coupled rotating machines, each of the machines having a rotor terminating in a rotor flange connected to a coupling, the coupling having a coupling flange corresponding to the rotor flange, comprising: a measuring system that measures a value related to misalignment of two or more machines and an interdisposed coupling; a processor that receives the misalignment values and computes a torque vector based on the misalignment values.

3. The system of claim 2, wherein the processor further compute potential a load factor based on the torque vector, the potential load factor indicating a relative amount of misalignment of the two or more machines and the interdisposed coupling.

4. The system of claim 2, wherein the torque vector is computed by the formula TT = TR1 +TR2, wherein TRI is the value of torque not transferred from a first machine to the coupling because of the misalignment and TR2 is the value of torque not transferred from the coupling to a second machine because of the misalignment.

5. The system of claim 4, wherein the value of TRI equals the torque generated by the first machine times the sine of the angle between a centerline of the rotor of the first machine and a centerline of the coupling, and wherein the value of TR2 equals the torque applied to the coupling times the sine of the angle between the centerline of the coupling and the centerline of the rotor of the second machine.

6. The system of claim 2 wherein the coupling is adapted to receive a measuring device at locations spaced radially about an outer portion of the coupling flange, and wherein the measuring device measures distances between a rotor flange face and a corresponding coupling flange face, the distances measured for each of the machines, the distances measured at least three locations on an outer radial portion of the coupling flange.

7. The system of claim 6, wherein the coupling is an ICAD coupling.

8. The system of claim 2, wherein the measuring device is an optical alignment device.

9. The system of claim 2, wherein the processor comprises; a program memory that stores operating programs; a data base that stores machine data; a telephone connection that receives data from the remote location; and a CPU that processes the machine data according to the operating programs.

10. The system of claim 9, wherein the operating programs comprise: a thermal growth module that computes thermal growth of the machines based on machine data and temperature changes, wherein the machine data includes machine dimensions; a journal movement module that computes shaft climb based on journal bearing clearances; and an overhung rotor module that computes rotor static tilt based on machine data and journal bearing clearances, wherein the machine data, thermal growth, shaft climb, and static tilt are stored in the data base.

11. The system of claim 10, wherein the thermal growth is computed in a vertical direction, and wherein the machine dimensions include a distance from a rotor to a bottom of a machine support foot.

12. The system of claim 11, wherein the temperature changes are the difference in temperature between an ambient temperature and a machine operating temperature.

13. The system of claim 12, wherein the machine operating temperature is an estimated value.

14. The system of claim 12, wherein the machine operating temperature is a measured value.

15. The system of claim 10, wherein the overhung rotor module computes static tilt based on one of a left overhung rotor, a right overhung rotor and both rotors overhung.

16. The system of claim 10, wherein the operating programs further comprise an optical conversion module, the optical conversion module computing angularity and off set based on data provided by an optical alignment system.

17. The system of claim 10, wherein at least one machine includes a gear box, and wherein the operating programs further comprise a gear box movement module, the gear box movement module computing gear movement based on journal bearing clearances and expected gear forces during machine operation, wherein the gear movement data are stored in the data base.

18. The system of claim 17, wherein the gear box includes a high speed shaft and a low speed shaft, and wherein the gear box movement module computes gear movement based on the high speed shaft being pinned.

19. The system of claim 18, wherein the operating programs produce a cold alignment check, the cold alignment check providing angularity and the off set for each machine, the angularity and of set based on the measured distances, the angularity and the off set including a compensation for thermal growth, rotor climb and static tilt.

20. The system of claim 18, wherein the angularity and off set include a compensation for gear movement.

21. The system of claim 17, wherein the operating programs produce a hot alignment check, the hot alignment providing angularity and off set for each machine, the angularity and off set based on the measured distances and including a compensation for rotor climb, gear movement and static tilt.

22. The system of claim 2, further comprising a display, the display showing values of angularity, off set and movement for each machine.

23. The system of claim 2, wherein the angularity, off set and movement are computed for a vertical plane and a horizontal plane.

24. The system of claim 2, wherein the coupling does not rotate during the distance measurements.

25. A system for determining a priority of alignments for machinery units, a machinery unit including two or more coupled rotating machines, comprising: a database that contains machinery data related to the machinery units; a processor coupled to the database; and a program memory coupled to the processor, the program memory storing a control program, wherein the data related to the machinery units includes alignment results and alignment specifications, and wherein the processor sorts the data related to the machinery units according to the control program to determine a priority of alignment.

26. The system of claim 25, wherein a machinery unit with a largest difference between alignment results and alignment specifications has a highest priority of alignment.

27. The system of claim 25, wherein the data related to the machinery units further comprises a potential load factor for each of the machinery units, and wherein a machinery unit with a largest load factor is selected as a machinery unit having a highest priority of alignment.

28. The system of claim 25, wherein the potential load factor is determined by calculating a torque vector related to machines in the machinery unit.

29. The system of claim 28, wherein the machinery unit, comprises: a first machine; a second machine; and a coupling disposed between the first and the second machines, the coupling connected to the first and the second machines, and wherein the torque vector is computed by the formula

TT = TR1 + TR2 wherein TRI is the value of torque not transferred from the first machine to the coupling because of the misalignment and TR2 is the value of torque not transferred from the coupling to the second machine because of the misalignment.

30. The system of claim 29, wherein the value of TRI equals the torque generated by the first machine times the sine of the angle between a centerline of a rotor of the first machine and a centerline of the coupling, and wherein the value of TR2 equals the torque applied to the coupling times the sine of the angle between the centerline of the coupling and the centerline of a rotor of the second machine.

31. The system of claim 25, wherein the data related to the machinery units further comprises a date since last alignment check, and wherein a machinery unit with a date of since last alignment check that exceed a threshold value is selected as a machinery unit having a highest priority of alignment.

32. The system of claim 31, wherein the threshold value is a periodic date.

33. The system of claim 32, wherein the periodic date is quarterly.

34. The system of claim 25, wherein the data related to the machinery units further comprises:

a potential load factor for each of the machinery units; and

a date since last alignment check; and wherein the control program sorts the

machinery units according to the data related to the machinery units to determine a machinery unit with the highest priority of alignment.

35. The system of claim 34, wherein the control program includes a weighting

factor, the weighting factor adjusting an importance of data related to the machinery

units, and wherein a machinery unit with a highest weighted result has the highest priority of alignment.

36. The system of claim 25, wherein the control program computes a potential energy cost associated with a misalignment of machines in the machinery unit.

37. A system for dynamic alignment of coupled, rotating machines, each of the

machines having rotor terminating in a rotor flange connected to a coupling, the

coupling having a coupling flange corresponding to the rotor flange, the coupling adapted to receive a measuring device at locations spaced radially about an outer portion of the coupling flange, comprising:

a measuring device that measures distances between a rotor flange face and a

corresponding coupling flange face, the distances measured for each of the machines,

the distances measured at least three locations on an outer radial portion of the

coupling flange; an interface coupled to the measuring device, the interface receiving the

distance measurements; and

a processor coupled to the interface that computes angularity and offset for

each of the machines and computes suggested movement values for one or more of

the machines based on the measured distances.

38. The system of claim 37, wherein the machines and the measuring device are

located at a local site and the processor and the interface are located at the local site.

39. The system of claim 38, wherein the measuring device is coupled to the

interface by a RS-232 connection.

40. The system of claim 37, wherein the machines, the measuring device, and the interface are located at a local site and the processor is located at a remote site.

41. The system of claim 40, wherein the interface includes a telephone connection,

and wherein the distance measurements are sent to the remote site using the

connection and one of a Public Switched Telephone Network and an Internet.

42. The system of claim 41, wherein the connection is a telephone modem.

43. The system of claim 42, wherein the processor comprises;

a program memory that stores operating programs; a data base that stores machine data; a telephone connection that receives data from the remote location; and

a CPU that processes the machine data according to the operating programs.

44. The system of claim 43, wherein the operating programs comprise:

a thermal growth module that computes thermal growth of the machines based on

machine data and temperature changes, wherein the machine data includes machine

dimensions; a journal movement module that computes shaft climb based on journal bearing

clearances; and an overhung rotor module that computes rotor static tilt based on machine data and

journal bearing clearances, wherein the machine data, thermal growth, shaft climb, and static

tilt are stored in the data base.

45. The system of claim 44, wherein the thermal growth is computed in a vertical direction, and wherein the machine dimensions include a distance from a rotor to a bottom of

a machine support foot.

46. The system of claim 44, wherein the temperature changes are the difference in

temperature between an ambient temperature and a machine operating temperature.

47. The system of claim 46, wherein the machine operating temperature is an estimated value.

48. The system of claim 46, wherein the machine operating temperature is a measured value.

49. The system of claim 44, wherein the overhung rotor module computes static tilt based

on one of a left overhung rotor, a right overhung rotor and both rotors overhung.

50. The system of claim 44, wherein the operating programs further comprise an optical

conversion module, the optical conversion module computing angularity and off set based on

data provided by an optical alignment system.

51. The system of claim 44, wherein at least one machine includes a gear box, and

wherein the operating programs further comprise a gear box movement module, the gear box

movement module computing gear movement based on journal bearing clearances and expected gear forces during machine operation, wherein the gear movement data are stored in

the data base.

52. The system of claim 51 , wherein the gear box includes a high speed pinion and a low

speed pinion, and wherein the gear box movement module computes gear movement based

on the high speed pinion being pinned.

53. The system of claim 52, wherein the operating programs produce a cold alignment,

the cold alignment providing angularity and offset for each machine, the angularity and off

set based on the measured distances, the angularity and offset including a compensation for thermal growth, rotor climb and static tilt.

54. The system of claim 53, wherein the angularity and offset include a compensation for

gear movement.

55. The system of claim 52, wherein the operating programs produce a hot alignment, the

hot alignment providing angularity and offset for each machine, the angularity and off set

based on the measured distances and including a compensation for rotor climb, gear movement and static tilt.

56. The system of claim 37, further comprising a display, the display showing values of

angularity, offset and movement for each machine.

57. The system of claim 37, wherein the angularity, off set and movement are computed for a vertical plane and a horizontal plane.

58. The system of claim 37, wherein the coupling does not rotate during the distance

measurements.

59. A method for dynamically aligning coupled, rotating machines, each of the machines

having a rotor terminating in a rotor flange connected to a coupling, the coupling having a

coupling flange corresponding to the rotor flange, the coupling adapted to receive a

measuring device at locations spaced radially about an outer portion of the coupling flange,

comprising: measuring distances between a rotor flange face and a corresponding coupling

flange face, the distances measured for each machine, comprising: (1) inserting a measuring device in the coupling flange,

(2) reading a value of distance,

(3) reading a value of measuring device inclination, and

(4) repeating steps (2) and (3) for at least two additional locations on the

coupling flange;

storing the distance measurements;

providing the distance measurements to a processor;

computing angularity and off set based on the distance measurements; and

computing suggested machine movements based on the computed angularity and off

set.

60. The method of claim 59, wherein the machines and the measuring device are located at a local site and the computations are performed by a processor located at the local site.

61. The method of claim 59, wherein the machines and the measuring device are located

at a local site and the computations are performed by a processor located at a remote site.

62. The method of claim 61, further comprising sending the distance measurements to the processor by way of a Public Switched Telephone Network.

63. The method of claim 61 , further comprising sending the measurements to the

processor by way of an Internet.

64. The method of claim 61, wherein the remote site includes a modem capable of receiving the distance measurements.

65. The method of claim 59, wherein the processor comprises:

a program memory that stores operating programs;

a data base that stores machine data; and a CPU that processes the machine data according to the operating programs.

66. The method of claim 59, further comprising computing thermal growth for the

machines, wherein the thermal growth is stored in the data base.

67. The method of claim 66, wherein the step of computing thermal growth

comprises: measuring a distance from a bottom of a machine support foot to a position on

a rotor;

determining ambient temperature at a location of the machine; determining a temperature of the machine; determining a temperature difference between the ambient temperature and a machine

temperature;

computing thermal growth based on the temperature difference, the measured

distance and a coefficient of thermal expansion; and storing the thermal growth.

68. The method of claim 67, wherein the ambient temperature and the machine

temperature are estimated.

69. The method of claim 68, wherein the ambient temperature and the machine

temperature are measured.

70. The method of claim 59, wherein a machine comprises a journal bearing, the

method further comprising computing rotor climb.

71. The method of claim 70, wherein the step of computing rotor climb comprises:

determining journal bearing diametrical clearances; determining rotor direction of rotation;

computing rotor climb in a vertical plane and in a horizontal plane; and storing the rotor climb.

72. The method of claim 59, wherein a machine comprises a journal bearing, the method further comprising computing rotor static tilt.

73. The method of claim 72, further comprising:

determining journal bearing diametrical clearances;

determining machine dimensions; computing the static tilt based on the diametrical clearances and the machinery

dimensions; and storing the static tilt.

74. The method of claim 73, wherein the machine dimensions comprise a distance from the journal bearing to the rotor flange.

75. The method of claim 72, wherein the method is performed for one of a left overhung

rotor, a right overhung rotor, and both rotors overhung.

76. The method of claim 72, wherein at least one machine is a gear box, the method

further comprising computing gear movement.

77. The method of claim 76, further comprising:

determining journal bearing diametrical clearances;

determining gear reactions;

computing gear movement using gear reactions and diametrical clearances; storing the gear movement.

78. The method of claim 59, further comprising:

converting optical alignment system readings to angularity and offset; and

storing the angularity and offset.

79. The method of claim 59, further comprising:

computing a cold alignment, the cold alignment providing angularity and off set for

each machine, the angularity and offset based on the distance measurements, the angularity

and offset including a compensation for thermal growth, rotor climb and static tilt.

80. The method of claim 79, wherein the angularity and off set include a

compensation for gear movement.

81. The method of claim 59, further comprising:

computing a hot alignment, the hot alignment providing angularity and off set for each

machine, the angularity and offset based on the distance measurements and including a

compensation for rotor climb and static tilt.

82. The method of claim 81, wherein the angularity and offset include a

compensation for gear movement.

83. The method of claim 59, further comprising displaying a dynamic alignment and the suggested movements.

84. The method of claim 83, wherein the dynamic alignment is displayed in a vertical plane and a horizontal plane.

85. A method for computing alignment tolerances for coupled, rotating machines, each of

the machines having a rotor terminating in a rotor flange connected to a coupling, the

coupling having a coupling flange corresponding to the rotor flange, the coupling adapted to

receive a measuring device at locations spaced radially about an outer portion of the coupling

flange, comprising:

determining thermal growth;

computing a first angularity and offset based on the thermal growth.

86. The method of claim 85, further comprising: determining static tilt; determining rotor climb; determining gear movement; computing a second angularity and offset based on the gear movement, rotor climb and static tilt; and storing the second and the first angularity and the off set in a data base.

87. The method of claim 86, further comprising: computing cold alignment tolerances using the first and the second angularity and off set values; computing hot alignment tolerances using the second angularity and offset values.