Shaft Alignment Calculation Excel

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LEVELLING, ALIGNMENT AND CENTERING OF SUSPENDED TYPE VERTICAL MACHINE1. 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: -1.1Thrust bearing is level to the optimum level1.2Thrust bearing or Upper bracket elevation is set to give corect turbine runner, elevation during normal opration.1.3The axis of Turbine and Generator shaft are in one vertical line1.4The Turbine runner centre and Generator rotor center concide with centre lines of stay ring and stator core respectivelyFor the process with respect to levelling, alignment and centralising following general sequence can be followed:2. STARTING CHECKS:2.1.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 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.2.2.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 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.2.3.The Thrust collar circumference to be divided to eight equi-distance circumferential points for the purpose of level 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.2.4.Arrangement to be made for positioning of dial gauge for measurement purpose and correct seating position for taking reading.2.5.All dial gauges (at least 10 numbers) are to be checked for physical healthyness and for the correctness of reading.2.6.For checking of level block level or spirit level with 1 in 50000 accuracy can be used.2.7.For taking level reading block level to be placed on thrust collar surface and to be set to zero.3. SETTING OF THRUST BEARING ELEVATION:3.1Checks the soleplates and bracket holding down bolts are tightened.3.2The bracket elevation can be set by adjusting the shims and it is to be ensured that the turbine runner will be at the desired level under running conditins.3.3.Allowance must be made for deflectionof the bracket and thrust bearing spring under normal load (I.e. Weight of rotating parts and hydraulic thrust)a).

Bracket deflection at normal load Expected Deflection: ab). Bracket deflection with Rotor and shaft load alone Expected Deflection: bc). Spring deflection at normal load Expected Deflection: cd). Spring deflection with Rotor and shaft weight alone Expected Deflection: d3.4.Turbine erector will advice the amount (T) by which the turbine coupling is below the normal running position. The Generator 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)) mm3.5It is essential that any adjustment of the bearing bracket shims made to obtain the correct coupling gap must precisely the same (by micrometer measurement) at each bracket feet, other wise the bracket will be thrown out of level.4. LEVELLING OF THRUST BEARING:4.1The generator Rotor is supported at the thrust bearing but not coupled to the turbine shaft.4.2Fit four of the guide bearing pads of generator guide bearing which is nearer to the thrust bearing with alignment pivot at 45º 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.4.3.Place precision level ( 0.02 mm in per division per meter or 1 in 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 given4.4.The Rotor is rotated thruogh 45º and the level gauge reading is noted.The same procedure is repeated for 90º, 135º, 180º, 225º, 270º, 315º and 360º rotation.NOTE:Before starting rotation HS system to be put on and after rotating 45º HS system to be put off.

After each rotation through 45º 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.4.5.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 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 50000.4.6.To obtain the required level accuracy, the shims under thrust bearing bracket feet are adjusted. Minimum number of the shims for a given adjustment should be used i.e. Thicker shims are to be used whereever possible.4.7.After correction of level or after achieving required level accuracy rotor alignment process to be started.5. ALIGNMENT OF ROTOR5.1.Set up two dial gauges each on the guide bearing journel surface nearest to Thrust bearing and at the Generator coupling in two mutually perpendicular directions X and Y (Down Stream). The mean value of the readings in X and Y axis is then used.5.2.Rotate the rotor through 45º, 90º, 135º, 180º, 225º, 270º, 315º and 360º.

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:XAXISLEVEL 2 3 4 5 6 7 8 1 2ANGLE OF ROTOR 0º 45º 90º 135º 180º 225º 270º 315º 360ºGEN. COUPLING (a)GEN. UPPER GUIDE BRG. LOWER GUIDE BRG.

©d=c-be=a-bYAXISLEVEL 8 1 2 3 4 5 6 7 8ANGLE OF ROTOR 0º 45º 90º 135º 180º 225º 270º 315º 360ºGEN. COUPLING (a)GEN. UPPER GUIDE BRG. LOWER GUIDE BRG. ©d=c-be=a-bNOTE:The reading at 0º and 360º 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 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.5.4.After applying necessary correction to keep the throw at Generator lower guide bearing and Generator coupling flange to 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.6.1.Pull the turbine shaft towards the generator shaft and couple the flanges by permanent bolts. The force of tightening the bolts should be identical.The diametrically opposite bolts should be tightened first.Technical requirement related to shaft tightening arrangement to be followed.6.2.Remove the turbine guide pads and the seals and the turbine support so that the shaft is suspended freely from the thust bearing.6.3.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 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.6.4.Fit the gauges on the turbine guide bearing journel level in X and Y Axis.6.5.Rotate the rotor through 45º, 90º,135º, 180º, 225º, 270º, 315º and 360º. The dial gauge reading are recorded in the format given below in clause 6.7.

For taking reading process as described above to be followed.6.6. FORMATE FOR ALIGNMENT READING6.6.1.Format for suspended type generatorXAXISLEVEL 2 3 4 5 6 7 8 1 2ANGLE OF ROTOR 0º 45º 90º 135º 180º 225º 270º 315º 360ºTURBINE G B (a)GEN. UPPER GUIDE BRG.(b)GEN. LOWER GUIDE BRG.(c)d=c-be=a-bYAXISLEVEL 8 1 2 3 4 5 6 7 8ANGLE OF ROTOR 0º 45º 90º 135º 180º 225º 270º 315º 360ºTURBINE G B (a)GEN. UPPER GUIDE BRG.(b)GEN. LOWER GUIDE BRG.(c)d=c-be=a-bNOTE:The note in para 5.3 will also apply here.6.7.As per NEMA standards the maximum throw circle diameter permitted at the turbine guide bearing is determined by formula:-0.05 L / D in mmWhere 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.6.8.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 shaft train can be done scrapping of end surface of turbine or generator shaft or by shimming of stainless steel packing placed between flanges of Turbine and Generator shaft coupling. Applied linear algebra ben noble and james w. daniel pdf. Packing should be graded with steps covering not less than 1/4th radial depth of flange.6.9.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.