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ALIGNMENT OF

TURBINE
GENERATOR
PRESENTATION BY
ANANDA
GOWROW SHETTY

CONTENTS
ALIGNMENT.
OBJECTIVE OF TURBINE, GEARBOX AND ALTERNATOR ALIGNMENT.
HUB SHRINK FIT
INSTRUMENTS IN ALIGNMENT OF TG SET.
PARTS INVOLVED IN ALIGNMENT OF TG SET.
STEPS INVOLVED IN ALIGNMENT
GROUTING OF TURBINE AND ALTERNATOR
PLACING OF CONDENSER
QUALITY CHECKS.
OBSERVATION MADE AT SITE
SUGGESTIONS.
CONCLUSION.

ALIGNMENT
ALIGNMENT:
It is the adjustment of an object in relation with other object
(or)
A static orientation of some object or set of objects in relation to
other.

OBJECTIVE OF TURBINE, GEARBOX AND


ALTERNATOR ALIGNMENT
To ensure axis of turbine rotor and pinion and also axis of
gear and alternator shaft are co-axial at hot running condition
and it is parallel to the ground.

To avoid incorrect meshing of gears, over heating of


bearings and to reduce vibrations.

To increase the life of couplings.

HUB SHRINK FITTING METHOD


Vessel
1. Heat the hub with the help of a
heating source using transformer
oil up to 200c .
2. Slow heating should be done
for uniform heating.
3. Once the required temperature
is attained measure the dimension
of inner diameter of the hub.

Transformer oil
(~200c for 3 hrs)
Coupling hub
support

Heating source

4. If required expansion is achieved takeout the hub and fix it to the alternator
shaft and place the key b/w the hub and shaft
56

-0.03
-0.21

-0.074

56

0.15
0.20

12

-0.16

20

32

62

56

250

+0.042
+0.017

key
Max interference= 0.092mm
Min interference=0.047mm

Alternator shaft

250

-0.03
-0.05

Coupling hub

INSTRUMENTS AND EQUIPMENTS


USED IN ALIGNMENT

Master level
Dial indicators
Dial indicator holder
Feeler gauges
Vernier caliper
Inside and outside micrometer
Plumb
Hammer
Spanner
Hydraulic jack
F-rod

PARTS INVOLVED IN ALIGNMENT OF TG SET

Turbine rotor
Pinion shaft
Gear shaft
Alternator rotor
Leveling pads
Taper wedges
Shim plates
Jacking screws
Foundation bolts and nuts
Barring gear

SYSTEM SPECIFICATION
DBSE of SCG-3 -

HSC - 550mm

LSC 500mm

Master level reading on levelling pads - 0.02 mm/m


Dimension of shim plate

- 75mm*150mm*X (0.05 to 1mm)

Dimension of packing plate - 75mm*150mm*X (1 to 25mm)


Dump and float of rotor

- 0.8 to 0.9 & 0.25 to 0.3mm

Dimension of taper wedge - 75mm*150mm*(14 to 20 mm)


=2.29

ALIGNMENT PROCEDURE FOR HSC


1.
2.

3.

4.

Turbine and gear box unit is


placed on the foundation block.
Using jacking screw lift the
turbine approximately to a height of
grouting thickness of 50mm and
Place shim plates or taper wedges
with additional steel plates if
required in between sole plate and
packer plate to support.
Check level of turbine at each
leveling pad and compare it with
the values of QA report received
from shop floor.
Insert the foundation bolts from
bottom and hand tighten the
foundation bolt, ensure that anchor
plate is having maximum contact
with the concrete surface .

Foundation bolt
Jacking screw
Taper wedges

Master level

sole plate

ALIGNMENT PROCEDURE FOR HSC


5.

A dial indicator holder is made to fix


two dial indicators ,which is held by one base
and which will be connected to the turbine
rotor flange using nut and bolt.

6.

One of the dial indicator will be


placed on the pinion flange face to check
parallelism.

The second dial indicator will be


placed on the radial surface of the pinion
flange to check the radial out .

Rough reading of radial run out and


parallelism between the flanges has to be
recorded after leveling the base plate using
master level.

Tighten the foundation bolts and check the


level and alignment reading.

10

Repeat the procedure of tightening and


loosening of foundation bolt to get alignment
reading and level reading with in the
tolerance .

PROCEDURE FOLLOWED DURING FINAL ALIGNMENT OF HSC


RADIAL(DESIGN)

FACIAL(DESIGN)

0.00

0.40

RADIAL (AT SITE)

0.00

0.40

0.80
(TOLERANCE= 0.05mm)

0.00

FACIAL(AT SITE)

0.00

0.00

0.00

0.30

0.00

0.60

0.90

-0.01

+0.01

0.00

(TOLERANCE= 0.05mm)

INFERENCE: According to the requirement the side out is zero but from the
reading pinion axis is (0.60-0.30=0.30) 0.15 mm to the right of rotor axis and the
pinion axis which has to be 0.40mm down from rotor axis is down by 0.45mm.

PROCEDURE FOLLLOWED DURING FINAL ALIGNMENT OF HSC


RADIAL(DESIGN)

FACIAL(DESIGN)

0.00

0.40

RADIAL (AT SITE)

0.00

0.40

0.80
(TOLERANCE= 0.05mm)

0.00

FACIAL(AT SITE)

0.00

0.00

0.00

0.30

0.00

0.60

0.90

-0.01

+0.01

0.00

(TOLERANCE= 0.05mm)

ACTION:
Foundation bolts under rotor casing on the right side seeing from steam end are tighten so that
rotor shifts to right so that side out reduces.
Gear box is slightly lifted by hammering taper wedges between sole plate and packer plate
under gear box so that 0.90mm reduces to 0.8mm.

ALIGNMENT PROCEDURE FOR LSC WITH TDPS ALTERNATOR

Sole plate
Foundation bolt

ALIGNMENT PROCEDURE FOR LSC WITH TDPS ALTERNATOR


1.
2.
3.
4.

Alternator should be placed to match centerline line of alternator with that of gear
shaft.
Level the alternator by placing master level on the sole plate of alternator
High speed coupling must be removed during low speed alignment.
The gear wheel must be positioned in its mid position and alternator in its magnetic
center position and get the required DBSE.
Match this marked line
with the step as shown

ALIGNMENT PROCEDURE FOR LSC WITH TDPS ALTERNATOR

5.

6.

Using the jacking screw


set
the
height
of
alternator to a height of
gear wheel axis and pack
the gap between sole
plate and packer plate
with taper wedge and
shim
plate
simultaneously.
Align the alternator to
get parallelism with in
0.02 mm and radial
runout as per design with
a tolerance of 0.05 mm.

ALIGNMENT PROCEDURE FOR LSC WITH TDPS ALTERNATOR


RADIAL(DESIGN)

FACIAL(DESIGN)

0.00

0.19

RADIAL (AT SITE)

0.00

-0.27

-0.08

(TOLERANCE= 0.05mm)

0.00

FACIAL(AT SITE)

0.00

0.00

0.00

0.00

-0.03

0.15

0.12

-0.01

+0.00

0.02

(TOLERANCE= 0.05mm)

INFERENCE: According to the requirement the alternator axis should have been to the
left of gear wheel axis by 0.23mm seeing from steam end but it is (0.15+0.03=0.18)
0.09mm and alternator axis should have been 0.04mm above gear wheel axis but it is
down by 0.06 mm.

ALIGNMENT PROCEDURE FOR LSC WITH TDPS ALTERNATOR


RADIAL(DESIGN)

FACIAL(DESIGN)

0.00

0.19

RADIAL (AT SITE)

0.00

-0.27

-0.08

(TOLERANCE=0.05mm)

0.00

FACIAL(AT SITE)

0.00

0.00

0.00

0.00

-0.03

0.15

0.12

-0.01

+0.00

0.02

(TOLERANCE= 0.05mm)

Action:
To make the alternator axis to be above gear wheel axis lift the alternator by hammering the
taper wedge between alternator sole plate and alternators packer plate to a height of 0.1mm.
Shift alternator towards left by 0.14 mm by jacking on right side of the alternator.
To correct facial we need to lift exciter side of the alternator or take it down at the front.

GROUTING OF TURBINE AND ALTERNATOR


1. Once the alignment is over TG set is ready for grouting
2. Calculate the volume of grouting cement mixture required to cover the
grouting area.
3. Build restraint around the turbine, generator and exhaust cutout.
4. Prepare the grouting mixture using a grouting mixer in the ratio of 8 liters
of water for every 50 kg of grouting cement
5. Pour this mixture continuously without giving time for grouting cement get
dry in b/w till the whole grouting area is covered with grouting mixture.
6. To get uniform distribution of grouting cement all over the area we should
use vibrator and ensure grouting cement flows out at the exhaust cut out.
7. Then the system is left for seven days for complete curing.

ERECTION OF CONDENSER SYSTEM


1. Condenser has two stools for support.
2. The condenser unit should be placed on one concrete support stool,
cast as per drawing.
3. Position condenser to match with center line of turbine exhaust flange in
both the axis.
4. Support the other end of condenser on temporary support.

CONDENSER ALIGNMENT

Alignment of condenser starts

with fixing of spool piece with


turbine exhaust flange.
80% blue matching of spool piece
flange is achieved by using a glass
slab of 10 to 15mm thick and then
it is bolted to the turbine exhaust
flange.

Exhaust
flange
spool
Bellow
Condenser
inlet flange

ALIGNMENT OF CONDENSER SYSTEM


Insert the coupler over the
spool piece and tack weld.
Now lift the bellow piece and
place it in b/w spool and
condenser inlet flange.
Maintain a gap of 15 to 25
mm b/w spool piece to
bellow.
Remove the tack weld,
place the coupler in
position so that the coupler
covers both spool piece and
bellow.
Weld coupler to both spool
piece and bellow.

ALIGNMENT OF CONDENSER SYSTEM


Bellow

By adjusting the
condenser ,align the
center line of the
condenser with that
of turbine exhaust.
Grout
the
fixed
support.

Connecting
flange

Condenser
Cooling water
outlet

Cooling water
inlet

MS plate and TEFLON sheet for sliding support.


Condenser leg

Teflon
Ms plate
Concrete stool

QUALITY CHECKS
1. Interference of coupling hub and alternator shaft (0.05 to
0.1mm ).
2. Level on each leveling pad with 0.02 mm/m allowance on
values given from QA report of shop floor
3. Turbine level on bearing journal (0.02 mm/m.).
4. DBSE (0.3 to 0.5mm).
5. Final alignment readings
Radial (0.05mm)
Facial (0.02mm)

COMMON CHECKS
1.
2.
3.
4.
5.
6.
7.
8.
9.

Elevation of each packer plate.


Whether load is acting on all shim plates .
Tightening of all foundation bolts.
Whether foundation bolt anchor plate is having sufficient contact .
There is clearance all around the foundation bolt.
Parallelism of all steam pipes connected to turbine is within (+/- 0.15 to 0.2mm)
and all bolts are freely moving in the bolt holes.
Using glass slab of 10 to 12 mm thick , spool piece is blue matched for 80%
before it is connected to exhaust flange
Care should be taken that alignment is not disturbed during welding of bellow and
spool using coupler.
Proper earthing should be provided while welding

OBSERVATION MADE AT SITE


1.

KIRI DYES: Foundation


bolt broken.

2.

SUTLEJ TEXTILES:
Foundation bolt deformed.

3.

KIRI DYES: Contractor


had filed the leveling pads.

OBSERVATION MADE AT SITE


4. KIRI DYES: Hand grinded
packer plate were used.
5.

KIRI DYES: Turbine


sole plate was deformed.

6. KIRI DYES: Seating area


of taper wedge and sole
plate is less.

SUGGESTION
1.
2.
3.
4.

Using of taper wedge is easier than shim


plate.
Hand grinded ms plates for extra packing
plates should not be used.
Torque wrench should be provided for
tightening of foundation bolt.
Taper wedges were deformed due to direct
hammering .

CONCLUSION
Alignment is the most important procedure done for
efficient and effective running of turbine for a longer period of
time.

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