LEVELLING , ALIGNMENT AND CENTERING OF SUSPENDED TYPE VERTICAL MACHINE

LEVELLING , ALIGNMENT AND CENTERING OF SUSPENDED TYPE

VERTICAL MACHINE

1. INTRODUCTION:
Levelling and alignment along with centralising are most
important in the erection of hydro generator. Trouble free
operation of the machine depends on satifactory achievement of
level alignment and centralising of the rotor. These operations
must ensure that : -

1.1 Thrust bearing is level to the optimum level

Thrust bearing or Upper bracket elevation is set to give corect
1.2
turbine runner, elevation during normal opration.
1.3 The axis of Turbine and Generator shaft are in one vertical line
The Turbine runner centre and Generator rotor center concide
1.4
with centre lines of stay ring and stator core respectively
For the process with respect to levelling , alignment and
centralising following general sequence can be followed:

2. STARTING CHECKS:
The turbnine shaft will have to be set truly vertical and central to
the stay ring by the turbine erector. The turbine shaft however ,
will be set lower than its normal running position to clear the
coupling spigot when generaor shaft is lowered . The generator
2.1.
erector has to satisfy him self that coupling spigot doesnot foul
with Generator shaft when lowered.In case of (Vertcal pelton
turbine) Turbine shaft was lowered on Nozzel alignment disc till
coupling of the turbine shaft with Generator shaft.
Dialing location and coupling face of UGB , LGB , TGB journel
surface , turbine & generator to be cleaned and polished with out
most care.It is to be noted that turbine shaft and generator shaft
coupling face cleaned and polished before lowering of rotor. In
2.2.
case of Tala machine in some cases dial gauge reading were also
taken in Top shaft and spider coupling and bottom shaft and
spider coupling to check generator shafts train aligned with its
own axis.
The Thrust collar circumference to be divided to eight equi-
distance circumferential points for the purpose of level
2.3. and alignment reading. The equi-distance points location to be
vertically transferred to all dialing location and outmost care to
be taken for the purpose.
Arrangement to be made for positioning of dial gauge for
2.4. measurement purpose and correct seating position for taking
reading.
All dial gauges (at least 10 numbers) are to be checked for
2.5.
physical healthyness and for the correctness of reading.
For checking of level block level or spirit level with 1 in
2.6.
50000 accuracy can be used.
For taking level reading block level to be placed on thrust collar
2.7.
surface and to be set to zero.

3. SETTING OF THRUST BEARING ELEVATION:

 Checks the soleplates and bracket holding down bolts are
3.1
tightened.
The bracket elevation can be set by adjusting the shims and it is
3.2 to be ensured that the turbine runner will be at the desired level
under running conditins.
Allowance must be made for deflectionof the bracket and thrust
3.3. bearing spring under normal load (I.e. weight of rotating parts
and hydraulic thrust)
a). Bracket deflection at normal load Expected Deflection : a
b). Bracket deflection with Rotor and shaft load alone Expected
Deflection : b
c). Spring deflection at normal load Expected Deflection : c
d). Spring deflection with Rotor and shaft weight alone Expected
Deflection : d

Turbine erector will advice the amount (T) by which the turbine
coupling is below the normal running position. The Generator
3.4. must then be set at a height above the turbine coupling by the
amount equal to T plus additional deflectionof the thrust bearing
at full load . This is equal to ( T + (a + c)- (b+d)) mm

It is essential that any adjustment of the bearing bracket shims

made to obtain the correct coupling gap must precisely the same
3.5
(by micrometer measurement) at each bracket feet , other wise
the bracket will be thrown out of level.
4. LEVELLING OF THRUST BEARING :
The generator Rotor is supported at the thrust bearing but not
4.1
coupled to the turbine shaft.
Fit four of the guide bearing pads of generator guide bearing
which is nearer to the thrust bearing withalignment pivot at 45
4.2 intervals. Close up the clearance to a minimum with pad locking
bar ,yet allowance to the Rotor to Rotate. Guide bearing pads are
to be applied with Servo prime 46 lubricant.
Place precision level ( 0.02 mm in per division per meter or 1 in
4.3. 50000 accuracy ) on the top face of the thrust collar in any
position. Set the level so that the bubble is exactly at the centre.
NOTE:1) Level must be checked for zero error.
2). The level must be firmly secured to avoid jerks while rotation
is being given
The Rotor is rotated thruogh 45 and the level gauge reading is
4.4. noted.The same procedure is repeated for 90 , 135 , 180 , 225
, 270 , 315 and 360 rotation.
Before starting rotation HS system to be put on and after
rotating 45 HS system to be put off. After each rotation through
NOTE
45 and putting off of HS system wait time of around 120
:
seconds to be allowed to elapsed before taking reading to get
more accurate reading.
For a truly horizontal thrust face , the reading of the precision
level would be constant. It is not expected that it will be
practicable to achieve precisely the same level reading in all
4.5.
directions of the shaft and the results can be taken as
satisfactory if the maximum reading is within 1 division of the
level with a level accuracy of 1 in 50000.
 To obtain the required level accuracy , the shims under thrust
bearing bracket feet are adjusted. Minimum number of the shims
4.6.
for a given adjustment should be used i.e. thicker shims are to
be used whereever possible.
After correction of level or after achieving required level accuracy
4.7.
rotor alignment process to be started.

5. ALIGNMENT OF ROTOR

Set up two dial gauges each on the guide bearing journel surface
nearest to Thrust bearing and at the Generator coupling in two
5.1.
mutually perpendicular directions X and Y (Down Stream). The
mean value of the readings in X and Y axis is then used.
Rotate the rotor through 45 , 90 , 135 , 180 , 225, 270 ,
5.2. 315 and 360. Record readings of the dial gauges in the foramte
given below as per process as described as above:

5.3. The accuracy of alignment is computed from the following table :

X_AXIS
LEVEL 2 3 4 5 6 7 8 1 2
ANGLE OF ROTOR 0 45 90 135 180 225 270 315 360
GEN. COUPLING (a)
GEN. UPPER GUIDE BRG. (b)
GEN. LOWER GUIDE BRG.
d=c-b
e=a-b

Y_AXIS
LEVEL 8 1 2 3 4 5 6 7 8
ANGLE OF ROTOR 0 45 90 135 180 225 270 315 360
GEN. COUPLING (a)
GEN. UPPER GUIDE BRG. (b)
GEN. LOWER GUIDE BRG.
d=c-b
e=a-b

The reading at 0 and 360 should be same within the tolerance

of reading accuracy (minimum permissible closing error). If these
reading consistently show difference , there is possibility that the
shaft is not freely rotating. The oil retaining sleeve or some such
NOTE:other component may be touching the rotor. This has to be
checked.It is to be checked wheather any jerk is produced while
rotating the rotor which affects the initial reading. If so , reason
for jerk to be evaluated and necessary correction applied or the
initial reading should be taken after the jerk.

After applying necessary correction to keep the throw at

Generator lower guide bearing and Generator coupling flange to
5.4.
a desired level as per standard , Turbine and Generator shaft to
be coupled for further combined alignment checking.

6. COMBINED ROTATIONAL CHECKS ON GENERATOR AND TURBINE

SHAFTS.
 Pull the turbine shaft towards the generator shaft and couple the
flanges by permanent bolts. The force of tightening the bolts
6.1. should be identical.The diametrically opposite bolts should be
tightened first.Technical requirement related to shaft tightening
arrangement to be followed.
Remove the turbine guide pads and the seals and the turbine
6.2. support so that the shaft is suspended freely from the thust
bearing.
The gap between the turbine runner and stay ring should agree
with the setting obtained by the turbine erector while
centralising the shaft. The generator guide bearing are to be
6.3.
adjusted if necessary. If the centralising affects the bracket
centering by more than 0.25 mm , the bracket will also have to
be centralised , which is as followed normally.
Fit the gauges on the turbine guide bearing journel level in X and
6.4.
Y Axis.
Rotate the rotor through 45 , 90 ,135 , 180 , 225 , 270
, 315 and 360. The dial gauge reading are recorded in the
6.5.
format given below in clause 6.7 . For taking reading process as
described above to be followed.
6.6. FORMATE FOR ALIGNMENT READING

6.6.1. Format for suspended type generator

X_AXIS
LEVEL 2 3 4 5 6 7 8 1 2
ANGLE OF ROTOR 0 45 90 135 180 225 270 315 360
TURBINE G B (a)
GEN. UPPER GUIDE BRG.(b)
GEN. LOWER GUIDE BRG.(c)
d=c-b
e=a-b

Y_AXIS
LEVEL 8 1 2 3 4 5 6 7 8
ANGLE OF ROTOR 0 45 90 135 180 225 270 315 360
TURBINE G B (a)
GEN. UPPER GUIDE BRG.(b)
GEN. LOWER GUIDE BRG.(c)
d=c-b
e=a-b

NOTE:The note in para 5.3 will also apply here.

As per NEMA standards the maximum throw circle diameter

6.7. permitted at the turbine guide bearing is determined by formula
:-

0.05 L / D in mm
 Where L is the distance between the generator thrust face and
turbine guide bearing, D is the out side diameter of the thrust
bearing. If by this standard the permissible throw the turbine
guide bearing clearance, the throw should be limited to a value of
a little below the turbine guide bearing radial clearances.
The throw at the bearing journals and flange is corrected if it
exceeds the permissible limit defined above. Small throw may be
corrected by differential tightening of the corresponding bolts of
flange connections. If the throw is considerably large , aligning of
6.8. shaft train can be done scrapping of end surface of turbine or
generator shaft orby shimming of stainless steel packing placed
between flanges of Turbine and Generator shaft coupling.
Packing should be graded with steps covering not less than
1/4th radial depth of flange.
After applying necessary correction to keep the throw at
Generator lower guide bearing and Turbine guide bearing to a
desired level as per standard. It may be necessary to change 'e'
and 'd' togerther. In such cases , shims have to be put or
scraping may have to be done at the surface between thrust
collar and runner disc..Onec throw has been brought to the
6.9.
acceptable limits , final level , alignment and centering reading to
be taken and if necessary throw reading at collector assembly
may noted (this requirement decided by Generator erector).The
process for throw checking in collector assemby as follows and
for details analysis same process may be adopted as for
Generator.
6.10. The collector is now assembled.
Fit two dial gauges each at one of the collector rings and at
generator guide bearing nearer to thrust bearing. Rotate the
6.11.
rotor 45 , 90 ,135 , 180 ,225 , 270 , 315 and 360. The dial
gauge readings are recoded in the format given below.

X_AXIS
LEVEL 2 3 4 5 6 7 8 1 2
ANGLE OF ROTOR 0 45 90 135 180 225 270 315 360
COLLECTOR RING (a)
GEN. GUIDE BRG. (b)
c=a-b

Y_AXIS
LEVEL 8 1 2 3 4 5 6 7 8
ANGLE OF ROTOR 0 45 90 135 180 225 270 315 360
COLLECTOR RING (a)
GEN. GUIDE BRG. (b)
c=a-b

The throw circle diameter as defined earlier should be limited to

6.12.
NEMA standars or 0.2 mm , whichever is lower.
The guide bearing pads of both the turbine and generator are
6.13.
fixed with the clearance stated in the appropriate drawings.
6.14. The Generator stator is centralised with respect to the rotor.
 The air agp length is measured both at the top and bottom of the
6.15. poles. Minimum gap at the pole centre is to be recorded. The air
gap measurement has to be taken at every pole.
The Rotor is now rotated and the air gap at one pole is recorded
rotating the pole through 45 , 90 ,135 ,180 ,225 , 270 ,
6.16. 315 and 360 position to get Rotor form with respect to fixed
point in Stator (D/S mark in Stator)and Stator form with respect
to particular pole of Rotor (usually pole no. 1).
The maximum variation of air gap length should be limited to 5
6.17. % of the normal value but a variation of 10 % can be allowed at a
few places.

7. MAGNETIC CENTERING

For magnetic centering the centre line of the rotor and stator
shall be at the same elevation during operation. To achieve this
following precaution are to be taken during erection.
During mounting of pole on rim assembly the centre line of every
7.1. pole is kept at the same elevation. To acheievd this the pole stope
height can be modified to suit on assembly.
As mentioned in clause 3.4 the Generator is set at higher
elevation. Therefore . At stand still condition the centre line of
rotor shall be at higher / lower elevation than stator centreline
7.2.
by the same amount as prescribed in the relevant drawing. To
achieve this shims shall be added or removed from the bottom of
stator sole plates.
The Levelling , Alignment and centering process described as
above to be applicable to suspended type vertical machine .The
same methodology for the application of levelling , centering
NOTE
and alignment of semi - umbrella & umbrella type vertical
:
machine can be adopted.But for calulation purpose values of 'd'
and 'e' to be considered based on the bearing location for those
type of machine.