Measure. Verify. Innovate. Understand.
Critical rotating equipment and their supporting structures are constantly responding to changes in temperature, loading, operational forces, and environmental conditions. Steam turbines, gas turbines, generators, compressors, foundations, soleplates, and structural supports all experience positional changes that can directly influence shaft alignment, bearing loading, piping stresses, equipment reliability, and long-term performance.
Understanding these changes requires far more than a single instrument or measurement technique.
Live ALIGN 3D™ is ROTATEK’s proprietary engineering measurement methodology that integrates complementary measurement technologies, custom-engineered tooling, independent verification techniques, and advanced engineering analysis to accurately quantify positional changes under actual operating conditions.
Rather than adapting the problem to fit available equipment, we engineer the measurement solution around the application. By selecting the most appropriate technologies for each project—and designing custom tooling when conventional methods are insufficient—Live ALIGN 3D™ enables ROTATEK to measure what others cannot and transform complex measurement data into actionable engineering insight.
Whether evaluating thermal growth, monitoring dynamic positional changes, verifying gas or steam turbine foundation movement, optimizing shaft alignment, or validating structural stability, Live ALIGN 3D™ delivers independently verified measurement data that improves confidence, reduces uncertainty, and supports better engineering decisions.
REAL-TIME Alignment Monitoring for Real-World Conditions
ROTATEK LiveAlign™ 3D is an advanced positional change monitoring service
integrating PERMALIGN laser monitoring systems with high-accuracy 3D laser tracker
metrology. This combined methodology delivers continuous, real-time alignment data
together with independent spatial verification of machine and foundation movement under actual operating conditions.
Every ROTATEK service includes a detailed graphical measurement report to support compliance, maintenance planning, and engineering review.
With cutting-edge technology, field-proven methods, and a relentless commitment to accuracy, ROTATEK is your trusted partner for real-world alignment monitoring and performance optimization.
how Can we Help you?
Our expert team is ready to help you with your next project. Explore the industries we serve or contact us to learn more.
The Four Principles
Measure
We utilize the measurement technology best suited for each application—not simply the equipment we have available. Live ALIGN 3D™ integrates complementary technologies including continuous laser monitoring, laser tracker metrology, precision shaft alignment systems, conventional optical methods, and other advanced measurement techniques to acquire the highest quality data possible.
Verify
Critical measurements are independently verified using complementary technologies whenever practical. Comparing independent measurement methods increases confidence, validates results, and reduces uncertainty when making critical engineering decisions.
Innovate
No two machines are alike, and many measurement challenges cannot be solved with standard tooling.
ROTATEK routinely designs and fabricates custom measurement fixtures, brackets, adapters, Invar tooling, optical targets, and specialized instrumentation to access difficult measurement locations and obtain data that would otherwise be impossible to collect.
Whether overcoming restricted access, extreme temperatures, line-of-sight limitations, or unique machine geometries, our custom-engineered tooling allows Live ALIGN 3D™ to measure what conventional methods cannot.
We don’t let tooling limitations dictate what can be measured—we engineer solutions to measure what matters.
Understand
Measurement alone has little value without engineering interpretation.
Live ALIGN 3D™ transforms millions of measurement points into meaningful engineering information through visualization, analysis, trend correlation, and practical recommendations that improve alignment, reliability, and maintenance planning.
Custom Measurement Tooling
One of the defining characteristics of Live ALIGN 3D™ is ROTATEK’s ability to engineer custom measurement solutions for unique applications.
Our engineering team designs and fabricates specialized tooling to overcome challenges such as:
- High-temperature measurement applications
- Restricted access
- Limited line-of-sight
- Non-contact measurement requirements
- Turbine and generator geometries
- Steam piping measurements
- Temporary and permanent sensor mounting
- Custom reference targets and fixtures
- Specialized Invar tooling to minimize thermal expansion
- One-of-a-kind measurement challenges
Because every machine presents unique constraints, every Live ALIGN 3D™ project can incorporate tooling specifically engineered for the application—not adapted from generic off-the-shelf hardware.
Continuous Alignment & Positional Change Monitoring
As part of the Live ALIGN 3D™ methodology, the PERMALIGN® continuous laser monitoring system provides real-time measurement of machine movement throughout startup, loading, steady-state operation, shutdown, and cooldown.
The system can be configured to support a variety of measurement objectives depending on the application.
For relative alignment monitoring, laser transmitters and sensors are mounted across the machine coupling to continuously measure changes in:
Vertical Offset
Horizontal Offset
Vertical Angularity
Horizontal Angularity
This configuration provides continuous visibility into relative alignment changes between adjacent machines as operating conditions change.
For absolute positional monitoring, optical targets are mounted directly to the machine while the laser monitoring instrumentation is referenced to stable structural points on the supporting foundation. This configuration measures the absolute displacement of the machine relative to the foundation throughout startup, loading, steady-state operation, and shutdown. This configuration continuously measures the movement of the machine relative to its foundation, allowing engineers to quantify thermal growth, foundation movement, and structural response.
Depending on the measurement objectives, Live ALIGN 3D™ may utilize either configuration independently or incorporate both during different phases of a project to develop a comprehensive understanding of equipment behavior.
When integrated with complementary measurement technologies and engineering analysis, these measurements help distinguish thermal growth from foundation movement, structural instability, mechanical looseness, or external influences such as piping forces.
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Real-Time Positional Change Monitoring and Trending
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Thermal Growth and Dynamic Movement Measurement
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Dynamic Movement Tracking
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Offline-to-Running (OL2R) Compensation – Using real-time displacement data to create precise alignment targets.
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Vibration and Process Monitoring and Trending
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Data Integration
Applications
Live ALIGN 3D™ is a flexible engineering methodology that can be adapted to a wide range of measurement challenges, including:
Rotating Equipment
- Steam turbines
- Gas turbines
- Generators
- Compressors
- Pumps
- Gearboxes
- Large industrial fans
- Marine propulsion systems
- Hydro turbines
Structural & Foundation Monitoring
- Steam turbine foundation movement
- Gas turbine foundation monitoring
- Generator foundation monitoring
- Soleplate movement and stability
- Foundation settlement and distortion
- Structural steel movement
- Pedestal and support movement
- Equipment skid movement
- Permanent and temporary displacement monitoring
Engineering Studies
- Thermal growth studies
- Dynamic positional change analysis
- Startup and shutdown monitoring
- Load change response
- Piping influence assessments
- Alignment target development
- Structural response evaluations
- Outage verification and validation
Why Live ALIGN 3D™ ?
No single measurement technology can fully characterize the behavior of large rotating equipment.
Each technology has unique strengths, limitations, and ideal applications. Live ALIGN 3D™ overcomes these limitations by integrating multiple complementary technologies into a single engineering methodology.
The result is a more complete understanding of machine behavior than can be achieved with any individual measurement system.
Equipment Used for Positional Change Monitoring
To ensure the most accurate and reliable data, ROTATEK uses a suite of advanced measurement and monitoring systems, including:
Permalign® Laser Monitoring Systems – Real-time, continuous movement tracking across critical couplings, machines and structures.
Live Trend Monitoring Systems – Real-time monitoring of movement tracking across machine couplings.
Laser Trackers – High-precision, large-volume measurement systems ideal for machine, and structural movement studies.
VibGuard® Advanced Online Vibration Monitoring Systems – Multi-channel vibration monitoring and analytics for dynamic behavior diagnosis.
These systems allow us to capture high-resolution data under live conditions—enabling informed alignment decisions based on how machinery behaves, not just how it’s built.
At ROTATEK, precision isn’t just a promise—it’s our certified standard. As an AS9100D and ISO 9001:2015 certified company, we back our commitment to quality with globally recognized benchmarks for excellence. With decades of field-proven expertise in precision measurement, laser alignment and 3D metrology, we deliver unmatched accuracy and reliability across aerospace, defense, power generation, marine, and general industry.
Our expert technicians adapt to the most demanding environments, offering tailored solutions with fast nationwide response times, 24/7 availability, and a proven quality management system built for mission-critical performance. We utilize cutting-edge equipment and industry-leading software to ensure your critical components meet the tightest tolerances—every time.