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.
Thrust bearing is level to the optimum level
1
1. Thrust bearing or Upper bracket elevation is set to give corect
2 turbine runner, elevation during normal opration.
1.
The axis of Turbine and Generator shaft are in one vertical line
3
1. The Turbine runner centre and Generator rotor center concide
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
2.1. 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.
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
2.2.
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.
The Thrust collar circumference to be divided to eight equi-
distance circumferential points for the purpose of level and
2.3. 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.
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:

Checks the soleplates and bracket holding down bolts are
3.1
tightened.
The bracket elevation can be set by adjusting the shims and it
3.2 is 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
3.3. thrust 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
3.5
same (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 with alignment pivot at
4.2 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.
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
4.3.
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 45º and the level gauge reading is
4.4. noted.The same procedure is repeated for 90º , 135º , 180º ,
225º , 270º , 315º and 360º rotation.
Before starting rotation HS system to be put on and after
rotating 45º HS system to be put off. After each rotation
NOTE
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.
For a truly horizontal thrust face , the reading of the precision
4.5. 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.
To obtain the required level accuracy , the shims under thrust
bearing bracket feet are adjusted. Minimum number of the
4.6.
shims 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
4.7.
accuracy 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
5.1. 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.
Rotate the rotor through 45º , 90º , 135º , 180º , 225º, 270º ,
5.2. 315º and 360º. Record readings of the dial gauges in the
foramte given below as per process as described as above:

The accuracy of alignment is computed from the following

5.3.
table :
X_AXIS
LEVEL 2 3 4 5 6 7 8 1 2
ANGLE OF ROTOR 0º 45º 90º 135º 180º 225º 270º 315º 360º
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 0º 45º 90º 135º 180º 225º 270º 315º 360º
GEN. COUPLING (a)
GEN. UPPER GUIDE BRG. (b)
GEN. LOWER GUIDE BRG. ©
d=c-b
e=a-b

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
NOTE:
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.

Pull the turbine shaft towards the generator shaft and couple
the flanges by permanent bolts. The force of tightening the
6.1. bolts 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
6.4.
and Y Axis.
Rotate the rotor through 45º , 90º ,135º , 180º ,
225º , 270º , 315º and 360º. The dial gauge reading are
6.5.
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 READING

6.6.1. Format for suspended type generator

X_AXIS
LEVEL 2 3 4 5 6 7 8 1 2
ANGLE OF ROTOR 0º 45º 90º 135º 180º 225º 270º 315º 360º
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 0º 45º 90º 135º 180º 225º 270º 315º 360º
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.

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 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 ,
6.8. 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. 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 45º , 90º ,135º , 180º ,225º , 270º , 315º and 360º. 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 0º 45º 90º 135º 180º 225º 270º 315º 360º
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 0º 45º 90º 135º 180º 225º 270º 315º 360º
COLLECTOR RING (a)
GEN. GUIDE BRG. (b)
c=a-b

The throw circle diameter as defined earlier should be limited

6.12.
to 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
6.15. the 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 45º , 90º ,135º ,180º ,225º ,
6.16. 270º , 315º and 360º 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
6.17. ± 5 % 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
7.1. every 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 ,
NOTE
centering 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.

ANALYSIS OF ALIGNMENT READING BY VECTORS RESULTANT METHODS

ANALYSIS OF ALIGNMENT READING BY VECTORS
RESULTANT METHODS

1. To analysis alignment reading one

will need the following items.

1.1. One good graph paper to plot the

displacement recorded in the X & Y direction.

1.2. One Good geometry box with pencil, eraser,

pencil sharpener , scale, compass, divider, protractor
& set squares, etc..
2. Now in the graph paper plot co-ordinate
axis and mark XX' and YY' axis.

3. To find vectors resultant the opposite vectors are

transferred to opposite direction. For example vector
5 shifted to vector 1 side (1-5) , vector 6 shifted to
vector 2 side (2-6) , vector 7 shifted to vector 3 side
(3-7) and vector 8 shifted to vector 4 side(4-6).

4. To find out the throw plot the vector group

resultant ( 1-5) & ( 3-7) ; (3-6) & (4-8) valus of ( x,y )
on a graph paper to a suitable scale. For example
plots points (3,-0.5) ; (1,7) ; (2 ,1.5) and (0,1.5) for
LGB ; (0,2.5) ; (3.5 , 2.5) ; (2.5 , -0.5) & (1.5 ,-2.5) for
TGB of combined alignmnet checking.

5. With vector group of (1-5) and (3-7) one

parallelogram is drawn and also its resultant of R-13 .
With vector group (3-6) and (4-8) parallelogram is
drawn and also its resultant R-28.Finally with the
resultant R-13 and R-28 total resultant parallelogram
is drawn and its resultant ploted to find net total
resultant.

5.1. From the ploted graph value of net resultant can

be calculated as per the scale of the graph. The
average value of the net resultant will be the throw
and the throw direction will be opposite to the
direction of force. The throw angle can be measured
from the ploted graph .

6. The throw at lower guide bearing and the turbine

guide bearing journel to be calculated and necessary
correction measure to be taken independently.

ANALYSIS OF ALIGNMENT READING BY THROW CIRCLE METHODS

ANALYSIS OF ALIGNMENT READING BY
THROW CIRCLE METHODS

1. To analysis alignment reading one

will need following items.

1.1. One good graph paper to plot the

displacement recorded in the X & Y direction.

1.2. One Good geometry box with pencil , eraser , pencil

sharpner , scale , compass , divider , protractor & set
squares etc..
2. Now in the graph paper plot co-ordinate
axis amd mark XX' and YY' axis.

3. To find out the throw plot the dispalcement of (x, y) on a

graph paper to a suitable scale. For example plots points
(0,0) ; (1,-3.5); (0,-1) ; (0.5 , -1) ; (1.5 ,0) ; (1.5,-6.5) ; (-1.5 ,-
3) ; (-6.5,-2) & (-3.5,0) LGB reading of combined alignmnet
checking.

4. Out of the total eight co-ordinate points three co-ordinate

points have to choosen in such a way that when a circle is
drawn with minimum radius will pass through thses three
points and also includes all other points within the circle.

4.1. To draw the circle first draw a triangle with the selected
three points. Then draw bisector of all the side. The cross
section of all bisector will be centre of the circle.Now taking
the cross section points as centre and any other points as
radius circle can be drawn.Diameter of such a circle should
be in close agreement with the throw (run out ) reading
obtain in factory. The throw will be half of the throw circle
diameter. The throw circle should not exceed 0.1 mm. The
angle of throw can obtained by drawing a line connecting
centre of co-ordinate axis and and centre of the circle.

5. The throw at lower guide bearing and the turbine guide

bearing journel to be calculated independently and
necessary correction measure to be taken independently.