Rotating equipment is a common type of asset used in a wide variety of industries. In this article, we’ll discuss the different types of rotating equipment and why proper alignment is key to maintaining your assets.
What is Rotating Equipment?
Rotating equipment refers to machines with rotating or spinning components that move during operation. This rotation facilitates the transfer of thermal, electric, or fluid energy into mechanical energy, which can then be used to perform work. This type of equipment is common in many industrial processes, such as manufacturing, oil and gas processing, power generation, and water treatment. Rotating equipment plays a pivotal role in many industrial operations.
Types of Rotating Equipment
There are many types of rotating equipment. While they are used for different purposes, all machines facilitate the transfer of energy from one form to another.
Pumps: Pumps move fluids and gases by using rotating equipment like impellers and rotors. There are many types of pumps, but common examples include centrifugal pumps and rotary pumps. Centrifugal pumps use a motor to rotate an impeller, converting kinetic energy into hydrodynamic energy. Rotary pumps are a type of positive displacement pump that moves fluids by trapping them in rotating components and forcing them from the inlet to the outlet.
Turbines: Gas turbines are engines that use combustion to produce steam, which then drives the turbine to generate mechanical power. They are often used in the power generation, oil, and gas industries.
Compressors: Compressors pressurize air or other types of gas. They’re powered by either rotating impellers or piston mechanisms. Compressors are crucial for running pneumatic-powered tools or moving gases.
Fans and blowers: Fans and blowers move air or gas. They work by generating airflow through rotating blades or impellers. They are commonly used in HVAC systems and many industrial processes.
Gearboxes: Gearboxes consist of gears and shafts that rotate to transfer mechanical power from a driving source, such as a motor, to another piece of equipment. Gearboxes modify the torque and speed between rotating equipment components.
Rotating Equipment vs. Static Equipment
Most industrial operations use both rotating equipment and static equipment. While both types of equipment are important, they perform very different functions and need different types of maintenance.
Static equipment, or fixed equipment, performs functions that don’t involve movement. Pressure vessels, storage tanks, heat exchangers, and boilers are all examples of static equipment.
Rotating equipment has parts that rotate or spin during use. This type of equipment is necessary for moving gases or fluids and for generating mechanical power. Alignment is an important part of maintenance for rotating equipment to ensure it continues operating correctly.
Misalignment in Rotating Equipment
Misalignment is a common problem for rotating equipment. An estimated 50% of failures in rotating equipment are caused by misalignment issues. This problem occurs when the centerlines of rotating shafts aren’t parallel with each other or when they are offset.
Since energy transfer depends on the rotation of the impeller or other component, any misalignment can cause serious operational issues. When the components aren’t positioned correctly during operation, problems like increased energy consumption, accelerated wear and tear on components, and complete machine failure can result.
There are several reasons misalignment occurs in rotating equipment:
- When a machine warms up, thermal expansion can cause its parts to shift and ultimately result in misalignment.
- Vibrations from normal equipment use cause alignment to shift over time.
- Factors like shaft deformation and wear and tear can contribute to misalignment.
Precise alignment with laser alignment tools can remedy these issues, accounting for factors such as thermal expansion to ensure that rotating equipment stays properly aligned even while in use.
Why are Laser Alignment Tools Key for Rotating Equipment?
Regular alignment should be a standard maintenance procedure for rotating equipment and should occur on a regular basis. However, traditional alignment tools like straight edges and dial indicators don’t account for factors like thermal expansion. Even when rotating equipment is aligned correctly at rest, thermal expansion, vibration, or other factors can cause misalignment while the equipment is in use, which is when alignment is most important.
Laser alignment tools use a combination of sensors and lasers to take measurements while the rotating equipment is at rest and while it is in use. The sensor detects the laser beam and collects data about the source and severity of misalignment, guiding users to make adjustments to the machine’s base to achieve proper alignment.
Not only are laser alignment tools more accurate than other methods, they are also more accessible to technicians. Traditional alignment methods require years of experience as well as specialized tools and knowledge to achieve perfect alignment. With a growing shortage of experienced technicians, laser alignment tools help bridge the knowledge gap and allow less experienced workers to perform measurements and adjustments.
Laser alignment tools help technicians achieve proper alignment and prevent mechanical failures. Aligning rotating equipment helps achieve a longer lifespan, reduces downtime, and reduces operating costs, all while keeping equipment running efficiently.
For more information on alignment tools for every industry, contact the experts at Prüftechnik.
