Before placement of Module / Rotor in position the coupling faces of all the rotors

are to be checked for concavity / convexity of their coupling faces. This can be
checked with the help of a thin rectangular lightweight straight edge. No concavity
of about 0.02 / 0.03 mm is permitted to manufacturing units.

It is checked by placing a straight edge across the coupling face and then measurement of the gaps
between the coupling face and straight edge. Gap mapping tells whether the coupling face surface is
having concavity or convexity. Facial runout is measured on the rotor faces. Convexity of any value,
concavity of more than 0.02 mm, high facial runout is corrected by means of manual scrapping of the
Coupling face.

Bearing assembly procedure

4. Ensure 0.03 feeler tightness on bearing parting plane. In case of any variation the matter may be referred
to designers.

5. Measure bore dia of the bearing and journal dia at site and ensure the oil clearances. If any discrepancy is
observed , designer may be referred.
6. Ensure torus/spherical contact with their seats at site. While checking the contact the seat may be bolted
with their pedestal. In case variation contact from their specified diagrams are noticed then following may be
carried out at site:-
a) In case of torus to cylindrical seats the line contact are recommended by designers. If these lines are not
straight and are in angle then the bearing may be rejected straight way and sent to works for rectification.
These line contact may be in a width of about 20 mm throughout on its seat leaving with area on both sides.
The contact may be wide in Center and then gradually reducing on sides. In case there is no contact is
achieved in the center and only sides are having contact then a feeler gap may be recorded in bottom. In case
if the bottom is tight to a feeler of 0.03 mm the bearing may be accepted at site without doing any
rectification.
b) In a reverse case the contact are achieved in center only though the 0.03 feeler is not going in the side. The
bearing may be still accepted at site. In case if the feeler is going in the bottom or in sides by 0.03 mm. the
bearing are not accepted at site and can be sent back for the rectification to the works. Similarly if the
contact are intermittent on its seat but in a straight line and no feeler is going the bearing may be accepted.
In case of very wide contact also the bearing may be sent back for the rectification. While checking these
contact very light color may be put on torus of the bearing. Before sending back the bearing to the works the
matter may be referred to designers and their concurrence is to be obtained. No scrapping/lapping is
recommended in these bearing for improvement of the contact.
c) In case of spherical to spherical bearing the contacts are called in the center like a moon shape. In these
bearings even full contact may be accepted. But in case if there are contact on sides and a feeler gap is
noticed on center then the bearing may not be accepted.
In such cases if the gap is upto 0.03 mm then the matching/lapping may be carried out at site. But in case of
higher gap the matter may be referred to designers. In case of reverse case if the feeler gap of 0.03 is noticed
on both sides of the bearing the bearing may not accepted at site and matter may be referred to designers.
15. Ensure good contact between journal and babbitt metal of the bearing in the center. Any minor high spot
may be removed from the babbitt metal while checking with blue color. Ensure full contact of shaft over the
jacking oil pocket also.

SWING CHECK
GENERAL DESCRIPTION
The swing check is the measurement of radial throw caused due to coupling face geometric form of the two
rotor coupled together. This is measured on opposite end of the coupling and at the free end of the rotor.
The higher swing check value may cause higher shaft vibration, higher bearing shell temperature etc. The
value of swing check depends on axial runout of coupling faces, the diameter of the coupling and the length
of the rotor. During the machining of rotors in the works some tolerances are permitted by Designer's on the
coupling faces of the rotor resulting to some swing check values. The maximum swing check values permitted
caused due to the above tolerance for different diameter and length of the rotor can be worked out from the
enclosed graph. However it is recommended to keep the minimum swing check values for better results
during operation of the machine.
In a multi rotor Turbine-Generator system it is essential to measure the swing check value in both extreme
end and where the weight of the rotors are light. For example 200/210 M.W. KWU machine with Russian
Generator and static excitation system the swing check values are measured on HP rotor front end only. In
500 M.W. machine the swing check values are measured in H.P. front end and on exciter rear end. After
having general experience of number of 200 MW & 500 MW units, a necessity is felt to measure swing check
value on IP rotor front end also for better results during operation of the units. This can be done initially
during erection with temporary coupling bolts on LP-IP coupling before reaming/honing of coupling. Any
variation in swing check values may be corrected without any hesitation during erection of machine. Any
compromise at erection stage may cause serious problem during operation of the unit and any correction
becomes much more tedious a later stage. The correction may be carried out either by interchanging the
coupling position or by correcting the coupling faces by scrapping/cutting in consultation of Designers.
PROCEDURE
1. Before placement of Module/Rotor in position the coupling faces of all the rotors are to be measured for
concavity/convexity of their coupling faces. This can be checked with the help of a thin rectangular light
weight straight edge. No convexity is permitted on these coupling faces however a concavity of about
0.03/0.04 mm is permitted. In case of any variation the matter may be referred to manufacturing units.
2. After placement of individual Module/Rotor the coupling faces are to be measured for axial runout before
taking up alignment of various rotors. The HP rotor rear coupling face can be measured after placing it on
both of its bearing. The IP rotor faces are to be measured after placing IP rear end on bearing and front end
on lifting tackle. Similarly L.P. rotor, may be placed on bearing on its rear end and front end supported on
lifting tackle. Any variation on axial runout on coupling faces for more then the 0.02 mm. may be referred to
Designer's before taking up further works.

A very high accuracy is required during manufacturing of these rotor shaft at works. The axial runout on the
coupling face may not exceed 0.02 mm. and an additional check is also made at works/site to ensure that the
geometry of the entire coupling surface does not deviate by more then the 0.02 mm. except the concavity on
the coupling face which is permitted upto 0.03/0.04 mm.
During the alignment of two coupling both are to be turned in same direction and by the same amount when
the measurement are taken to avoid the influence of the axial & radial runout present in the shaft caused
due to the machining.
PROCEDURE
1. Before placement of module/rotor in position check and record the coupling hole and journal dia of the
shaft.
2. Check coupling faces for the concavity/convexity with the help of a thin rectangular straight edge before
placement of module/rotor in position.
3. Check spigot and recess of the coupling and ensure their fitting before placement in position.
4. Place the module/rotor in position and check the radial runout of journal and axial runout of the coupling
faces independently of each shaft. During checking of radial and axial runout of the shaft place H.P. rotor on
both of its bearing and IP/LP rotor one end on its bearing and another end on the lifting tackle. The radial and
axial face runout on the shaft should be within 0.02 mm accuracy. Any variation may not be permitted here
and matter may be referred to the designer's.

5. The HP,IP & LP rotor are aligned together and then their couplings are made. After fully completion of
HP/IP & IP/LP coupling with tightening of their final bolts the complete shaft is cleared for Generator rotor
alignment.
6. During initial alignment of HP/IP & IP/LP rotor the radial checks are generally done with the help of depth
micrometer and axial gap are measured with the slip gauges. After completion of the radial alignment the
rotor are inserted in their spigot even with some minor variation in their axial gap values.

17. As for as possible ream/hone all the coupling bolts holes to same size. In exceptional cases only the
variation in hole sizes are permitted. Each hole during honing should be checked for bananas shape with the
help of a parallel ground straight pin of 0.02/0.03 undersize. No banana shape is permitted in any of the hole.
The hole should be made to 0.005 mm accuracy.
18. All the coupling bolts are to be machined and ground by 0.02/0.03 mm undersize then the hole dia. These
bolts are to be fitted with thumb pressure only and no additional force is recommended while fitting these
bolts.

22. During tightening of coupling the radial runout on journal and coupling may be checked at various stages
during tightening of bolts. The final coupled runout should not be more then 0.03 mm. on coupling and
journal of the shaft.

23. After final tightening of LP-IP and HP-IP coupling the swing check value on HP front rotor is to be
rechecked. In case of variation in value a proper correction is to be made with consultation of designer's. The
indifferent or unsequential tightening for achieving the swing check value or coupled runout value may be
fully avoided. this may cause unnecessary stresses on the coupling.