The alignment between your pump and motor, as well as the alignment of your pump and pipework, can shift whether you have a great installation and operation experience… or a disaster. 

This article is designed to equip you with an understanding of the importance of on-site alignment of long-coupled pumps, an overview of the issues it avoids, and a step-by-step guide on how to achieve a sound installation. 

The Importance of Pump-Motor Alignment 

Some installation protocols are simply non-negotiable. This is very much the case when it comes to the on-site alignment of your long-coupled pumps. 

Even minor misalignments will cause suboptimal operating efficiency, resulting in increased costs, inferior pumping performance and additional wear and tear – the costs of which far outweigh any time or money saved by skipping out on the on-site alignment process. 

Severe misalignments between the pump and motor are capable of wreaking havoc on your HVAC system, causing harsh vibration, excessive noise, and seal leakage. We have even seen shafts snap on pumps that had the onsite installation process skipped… not exactly a pleasant surprise for the project manager.  

The idea that you can skip this process if your long-coupled pumps are laser-aligned from the factory is a common misconception. Even couplings that are perfectly aligned when they’re shipped out of the workshop, such as Masterflow’s laser-aligned Bakerflow couplings, can have their perfect calibration compromised by freight transport, crane loading, and incorrect pipework connection. Once your pumps are delivered, it’s a must to make sure these factors don’t sabotage your system.  

How do I Keep My Project Safe?

Ensure your site alignment is completed by a competent technician. They should be equipped with a laser alignment machine and provide you with an alignment report for demonstrable performance and your peace of mind. 

Note that site alignment is NOT necessary for close-coupled pumps. Close-coupled pumps still require adjustment of pipework hangers to minimise the strain placed on your pumpset, but as they retain their laser alignment from factory rather than being disturbed by freight and loading, performing an alignment check of the coupling after delivery is not necessary.  

Alignment Checklist 

First, visually inspect the connection of your pump to the plantroom’s pipework. Ensure that the flexible rubber couplings shown in the below image are connected: 

Next, check the flexible rubber couplings on both the suction and discharge end. They must be connected to both ends. If roll grooved couplings are used, confirm that at least 3x style 177N flexible couplings are installed on both the pump suction and discharge pipework. The use of rigid 107N couplings is a common mistake – if these have been used, inform the customer. If flexible or roll grooved couplings are not used, the job will need to be suspended. Do not proceed any further until this is addressed. 

Your third step is to check that pipe hangers or suction diffusion are being used to support the rig. Pipe hangers are used to support ductwork, while suction diffusers help the pump remain free from foreign particles and provide proper flow conditions by reducing water turbulence. 

Step four is to check the mounting of isolation spring assemblies. The springs should be set up with the base plate as such that the springs are floating, not rigid. 

Next, set up your laser alignment machine and collect the initial readings. The reading should show a minimum of two ticks on the horizontal plane, indicating a pass on the horizontal offset and horizontal angle. If less than two ticks are shown, or shims of more than 4mm are required, this is an indication of poor pipework installation. Our pumps leave the workshop fully aligned, with 4 ticks. With correct pipework, it should be relatively easy to restore this alignment on site. 

Once these five checkpoints have been cleared, your coupling is aligned and ready to run.  

Masterflow to the Rescue 

If you don’t have an alignment specialist on hand, or you encounter issues throughout the 5 step process such as the wrong couplings being used, or pipework installation issues being discovered, Masterflow is here to help. 

Contact us for an on-site coupling alignment or inspection today and enjoy the confidence that comes with a thorough inspection and calibration performed by experienced experts.