Analysis of shaft alignment on vibration and motor power consumption in cooling water pumps

Motors and pumps are the crucial components for various industrial production processes such as manufacturing, oil and gas, and chemical processing. However, one common issue affecting their reliability and efficiency is shaft misalignment. Research indicates that 30–40% of major financial losses in industrial operations are caused by misalignment, while 42–50% of motor failures are due to bearing damage. It is caused by poor alignment, insufficient lubrication, or improper installation. This study focuses on evaluating the effect of shaft alignment on vibration levels and motor power consumption in a cooling water pump at the Koto Panjang Hydroelectric Power Plant. A quantitative experimental approach was applied to measure and compare equipment performance before and after alignment. Results show that alignment reduces the highest axial vibration velocity by 8.35 mm/s and vertical vibration by 1 mm/s. Furthermore, motor power consumption decreases by 8.35%, as demonstrated by a reduction in average motor current from 76.8 A to 71.2 A. The vibration pattern confirms the angular misalignment as the dominant factor contributing to instability. These findings show the importance of routine shaft alignment, not only for minimizing vibration and extending equipment lifespan but also for enhancing energy efficiency and reducing operational costs.