Turbine Generator Alignment

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© 2009 Electric Power Research Institute, Inc. All rights reserved. 1

Safety TIP for the day: Close Call
• A “close call” or accident without injury is

easy to shrug off and forget
• Hazard awareness is key to preventing
accidents before they happen.
• Report every accident, no matter how minor it
may seem at the time
• The next time it happens, it could result in
serious damage, injury or death.

Welcome to the 2010 EPRI Steam Turbine
Generator Technical Webcast
• Some housekeeping issues:
– This web cast is being recorded for future use by our

TG program members and will be posted, along with
the ppt. slides, on the EPRI.com TG program web site
http://www.epri.com/nsti/products/webcast.html
approximately one week after each session
– If you do not desire to be a participant in this recorded

web cast please disconnect now

Welcome to the 2010 EPRI Steam Turbine
Generator Technical webcast
• Some housekeeping issues (cont.):
– There will be a Q&A session at the end of the web

cast and the operator will give you directions on how
to ask your questions
– The operator will monitor and manage the questions

coming from the participants
– If you would like to use attendance at any of these

sessions for Professional Development Hours (PDH’s)
please send an e-mail to Alan Grunsky
(agrunsky@epri.com)

EPRI Alignment 101 Webcast – December 2010
Presenter: Don Osborne
Don Osborne retired from Duke Energy in 2008 with 35 years’ service in the
turbine-generator maintenance and engineering areas. He is now a turbine
consultant working with Mechtell, Inc. where he is involved in turbine-generator
vibration analysis and balancing along with large scale measurement and
alignment services.

Why is Alignment Important?
 Proper alignment of turbine components is essential for good turbine

operation. Poor alignment will contribute to excessive vibration, rubbing of
stationary components, and may affect the unit reliability.
 If the turbine is misaligned there is a significant opportunity for the shaft to
make contact with the stationary components and many times the rub will be
so severe you can not reach running speed.
 Shaft misalignment causes shaft bending at the couplings which can initiate
coupling and coupling bolt failures.
 Shaft misalignment also causes improper bearing loading.

 Every time a rub occurs the clearance gets a little or sometimes a lot larger
hence turbine performance losses.
 Bottom line, machinery misalignment is responsible for major expenditures in

the form of labor, machinery parts, and lost generation and reduced capacity.
 $$$$$$$$$$$$$$$$

Types of Alignment
 Turbine Generator alignment is the vertical and horizontal positioning of the rotating and stationary
components.
 Shaft alignment is best described by the use of a machine catenary curve, this curve is developed
by measuring the shaft position at each bearing and relating these positions to a straight line
through the machine that has been adjusted to the proper rotor position set points that are derived
from the rotor position data collected during disassembly.
 The example below represents the relationship of all the bearings and shafts in the unit relative to
the turbine-generator centerline.

Types of Alignment
• Section internal alignment is the vertical and horizontal relationship of the

stationary parts to the rotating shaft for a given section.

Where Do You Start? Pre-Outage Planning
 Locate and review the bearing/coupling alignment specifications for the type unit to
be inspected.
 Ensure any changes that have been made to the original alignment
specifications are documented.
Example:
1. No 1 bearing is to be elevated 0.050” above the line through bearings No. 2 - No. 8 which
are all set in line. This will make the HP rotor coupling 0.020” low to “A” LP rotor coupling.
2. The generator stator frame feet are machined at an angle so that the generator coupling
face is vertical and bearings No. 9 and No. 10 are not in a horizontal line. Suitable shims
should be placed under the generator feet so faces are parallel and the peripheries are in
line.

Pre-Outage Planning
 Review the as left alignment condition of the turbine-generator.

 How has the unit operated since the last inspection?
 Vibration
 Have there been any changes in the machines’ vibration signature since the last inspection?
 Do the shaft orbits show any evidence of high or low radial loading? If so this is a sign of misalignment.
 Orbit Example:
High radial loading Low radial load –

Journal following bearing geometry
This could lead to oil whip
 Bearing Temperatures
 Have there been any changes in bearing temperatures during the run cycle?
 Are any bearings running hotter or cooler than normal? If so this is a sign that the bearing is carrying
more or less of the load than the other bearings.
 Lube oil sample changes?
 Change of machine sound?
 Water Induction events?
 Locate and ensure all alignment tools are in good working order.

Data Collection
 Have all data sheets available for recording alignment measurements.

 Use automated spreadsheets where possible.
 The machine is down, cooled and off turning gear.
 Prior to removing the upper half of the shell/cylinder and before coupling disassembly
perform the following:
 Remove the bearing covers, upper half of the oil seals and outer packing/gland casings.
 Measure and record the oil seal and packing/gland seal radial clearances.
 Remove the outer most packing/gland seal segments from the lower halves.
 Remove the lower half of the oil seals.
 Measure radial rotor position in the exposed oil and packing/gland bores.
 Measure and record rotor axial position.
 If possible, roll the unit and measure runout on the shaft over hangs.
 If possible measure the shaft position (horizontal and vertical) at the bearings.
 This task would require special tooling such as a laser, total station, standard optics or photogrammetry.

Oil Seal Radial Clearance
 Measure and record steam and oil seal radial clearances.

Outer Packing/Gland Seal Radial Clearance

Rotor Radial Position Conventional
Measurement Examples
:

Rotor Axial Position Conventional
Measurement Examples
LOCATION LS RS
SQEALER RING .036 (TE) .031 (GE)
BAL RING TO N-1 CASING 0.613 0.586
BALANCE RING TO N-1 GRV 3 0.48 0.477
A CPLG TO N-4 GRV 3 N/A N/A
N-5 GRV 1 TO GE BAL GROOVE 7.951 7.9475

Shaft Overhang Runout Measurement Example:

Shaft Catenary Curve
This information will aid you in making alignment correction decisions.

Compare to OEM specifications and as left data from previous outages.

Preparation for Conventional 16 Point Coupling
Alignment Reading
 Ensure all coupling halves and spacers have a well-defined match mark prior
to disassemble.
 Disassemble the coupling and measure as found coupling alignment.
 Conventional coupling setup for a 16 point reading:
Indicator Mounted on Driver

or Turbine End Rim
Rotor 2
Rotor 1
GE
TE
Face Opening

Coupling Alignment
 16 point coupling reading process:

 Notes:
 Two consecutive, accurate and repeatable sets of readings shall be obtained.
 IF lube oil system is tagged out, lubricate bearings by hand while rolling rotors. Terrestic 460
or equivalent is the proper lubricant.
 Roll the rotors at least two revelations prior to starting alignment readings.
 Ensure the coupling turning pins or temporary bolting are loose each time the rotor is stopped
at a new position.
 Ensure the data is good prior to rolling to the next position i.e. top & bottom face readings are
equal to left & right within .001”.
 Process
1. Ensure the bearings twist and tilt are correct prior to starting alignment readings.
2. Align the assembly marks of each coupling to the left horizontal joint.
3. Mount an indicator on the TE coupling half at the 12 o'clock position. The indicator pin should
be reading the rim on the GE coupling half.
4. Zero the indicator at the 12 o'clock position and take a 4 point face reading.
5. Roll both rotors, stopping every 90 degrees and take a rim and 4 point face reading.
6. Recheck the rim reading when the assembly marks return to the left horizontal. (#1 position)

Bearing Twist and Tilt Setting

Coupling Alignment Data Sheet
 16 point coupling reading datasheet:

Thought You Were Finished? - More Data Collection
 After removing the upper half of the shell/cylinder and coupling disassembly,
measure the rotor positions at the same locations previously measured.
 After all upper half components have been removed – chart the turbine axial
and radial internal clearances.
 Prior to removing the rotor measure the rotor runout.
 After the rotor is removed:
 Visually inspect all bearings and record any abnormal wear due to improper
loading, twist or tilt. This is a good indicator of misalignment.
 Visually inspect oil seals, gland seals and all internal seals, record all rub
locations. This is also a very good indicator of misalignment.
 Visually inspect rotor journals and record any anomalies.
 Measure and record rotor journal dimensions.
 Take photos, photos and more photos!

Rotor Axial Charting
 Record clearance and compare to base line data.

 Your data sheets will be customized to fit your
machine.

Rotor Radial Charting

Rotor Run Out Measurement Examples
 Data measured with dial indicators

Bearing Visual Inspection
 Inspect all the bearings in the turbine train:

 Document unusual signs of wear or damage.
Bearing assembled with improper tilt Bearing misalignment to journal. Tilt

caused 100% of the load to be
carried by 60% of the bearing which
initiated babbitt wiping

Seal Visual Inspection
 Visually inspect oil seals, gland seals and all internal seals, record all rub locations. This is also a very good
indicator of misalignment.

Seal Rub Photos

Rotor Journal Inspection
 Visually inspect rotor journals and record any anomalies.

 Measure and record rotor journal dimensions.
Grooves cut into shaft journals

Rotor Journal Dimensions
 Measure the journal diameter at one inch increments along the journal length.
 These measurements are to be read at two locations that are 90 degrees apart.
 If journal dimensions vary more than 4 mils or are out of round by more than 1 mil, the
journal should be refinished.

Stationary Component Alignment
 There is usually no need to measure the stationary component alignment prior to

cleaning.
 Clean the stationary components and clean all fits, support blocks, shims etc.
 It is a good practice to perform “tops on” vs. “tops off” alignment of internal
components. This should be evaluated on a case by case basis with reference to
previous alignment documentation and impact on the outage schedule.
 Many folks have been successful using the tops off approach:
 As found stationary component positions are recorded as well as packing rubs, out of
roundness and shell deviations. All of this data is used to formulate theoretical tops on
position.
 After the components have been reinstalled, measure vertical and horizontal position
of each component from the predetermined line through the turbine.
 The line through the turbine was derived from the rotor position data taken during
disassembly.
 There are a number of ways to obtain these measurements; tight wire, laser, photogrammetry,
total station, mandrel with prox. probes, mandrel with dial indicators just to mention a few.

Stationary Component Alignment-2
 After evaluating the alignment data:

 The line set points my be adjusted if this should help the overall alignment of the
machine and then all the positions would be recalculated.
You may decide to move a cylinder instead of all the individual components.
Alignment is three-dimensional and there are a number of possible answers that
exist for finding the most efficient and cost-effective solution that meets the
specified criteria.
 Don’t forget to use all the information we have gathered to aid in this process.

Diaphragm Alignment Data Using a Tight Wire
After this data was evaluated the set line was adjusted and diaphragm positions recalculated.
True vertical position = sum left & right readings/2 and then subtract from bottom reading
True horizontal position = subtract the smallest side reading from the other side/2
General rule: diaphragms are to be set low by 1/3 packing clearance plus rotor sag.

Diaphragm Alignment Data Using Laser Tracker
+ X = Right Horiz + Y = High Vert

Methods of Moving Diaphragms & Blade Rings
GE Type
Support Bar/Block
General Electric generally allows a diaphragm to be

rolled by 1 mil per inch (0.025 mm per meter) of
diaphragm outer diameter. Then it is required to be
re-leveled. To re-level and maintain the horizontal
position an adjustment has to be made to the
centering pin.

Bearing Ring Elevation Pad Contact
(Some)
80% pad to ring fit contact is required and 100% contact around
lube oil supply holes.

Bearing Ring Elevation Pad Contact - 2
80% pad to ring fit contact is required and 100% contact around lube oil supply holes.
Note:
The bearing ring elevation pads have to be removed to change alignment shims, ensure the pad match
marks are lined up with the bearing ring match marks when the pads are reinstalled. Failure to do so
will cause shim change results to be unpredictable

Bearing Ring Elevation Pad Contact - 3
 All bearing ring elevation pad contact is to be verified and corrected as necessary prior
to bearing alignment. (some bearing ring designs do not have elevation pads)
 80% pad to ring fit contact is required and 100% contact around lube oil supply holes
that go through some pads.
 Blue checks should be made with the upper and lower half bearing rings bolted together.
 The rings should be installed into the ring fit and tightened in place with the outer retaining
bolts.
 Tightening should be adequate to simulate rotor weight. All of the alignment readings are to be
taken with the bearing rings bolted together as described.
 After satisfying all bearing pad contact, the bearings should be aligned to the specified
catenary curve.

Bearing Ring Without Elevation Pads
1970’s Vintage Westinghouse Bearing
Horizontal Movement Shim Each Side
Vertical Movement Shim Each Side

This surface requires 80% contact with pedestal fit.

Coupling Alignment
 When the steam turbine is installed initially, each bearing is set to a specified
elevation based on the machine's catenary curve (the shape of the shaft
centerline under gravity when supported by the bearings). Setting the
bearings to this elevation should achieve the target alignment at the
couplings. Small bearing moves are made to align the rotors within tolerance.
 Installation is generally the last time bearing elevations are measured by

many folks.
 If bearing alignment to the curve is not performed and one depends solely on
coupling alignment data to align the shafts, you may get backed into a corner
that is almost impossible to get out of in a timely manner.
 That being said, let’s move on to a coupling alignment example on a

machine where the bearings have not been adjusted to the specified
catenary curve since initial installation.

Coupling Alignment - 2
 Remember the stationary components are aligned, all seal clearances are
set and the unit is built except for coupling assembly.
 This is where you can get backed into that corner.
 Previously we measured the coupling alignment using the conventional 16 point

reading, the rim was measured with an indicator and parallel blocks were used to read
the face, just to cover all bases, we will use a laser tracker to measure the coupling
alignment this in this example.
 This example is a HP- 3LP turbine and only the ALP was inspected.
 When using lasers, total stations, photogrammetry and standard optics the data is in
absolute numbers from center line and parallel line. No dividing by 2.

As Found Coupling Alignment for ALP
A-Cplg. Spec. – HP .010 low to ALP; Face open .016 in bottom

B-Cplg. Spec. – ALP .015 high to BLP; Face open .028 in bottom

Rotor Dimensions and Formulas Used to
Calculate Alignment Corrections

Bearing Shim Changes to Correct Alignment

Bearing Shim Changes to Correct Alignment-2
 This turbine did not have bearing ring shim pads so the moves were straight
up, down, left and right.
 If the bearing rings had shim pads the shim changes would look like this.

As Left Coupling Alignment for ALP
A-Cplg. Spec. – HP .010 low to ALP; Face open .016 in bottom

B-Cplg. Spec. – ALP .015 high to BLP; Face open .028 in bottom
After making a fairly large bearing move on the two ALP bearings
this is a close as we could come to the alignment spec.

EPRI Alignment Publications
We have just scratched the surface here today – I encourage you obtain and
review the following EPRI documents for a more in-depth understanding of
alignment:
Guidelines for Reducing the Time and Cost of Turbine-Generator

Maintenance Overhauls and Inspections Volume 3: Balancing and Alignment.
1011014
EPRI Shaft Alignment Guide TR-112449
EPRI also has an alignment program – TGAlign – this is a multi-coupling

alignment program which is included in the Guidelines for Reducing the Time
and Cost of Turbine-Generator Maintenance Overhauls and Inspections.
Thank You for Your Time Today

Questions?
This web cast has been recorded for future use by our TG
program members and will be posted, along with the ppt.
slides, on the EPRI.com TG program web site
http://www.epri.com/nsti/products/webcast.html
approximately one week after each session.

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Audio toll free dial instructions

© 2009 Electric Power Research Institute, Inc. All rights reserved. 1

• A “close call” or accident without injury is

© 2009 Electric Power Research Institute, Inc. All rights reserved. 2

• Some housekeeping issues:

– This web cast is being recorded for future use by our

– If you do not desire to be a participant in this recorded

© 2009 Electric Power Research Institute, Inc. All rights reserved. 3

• Some housekeeping issues (cont.):

– There will be a Q&A session at the end of the web

– The operator will monitor and manage the questions

– If you would like to use attendance at any of these

© 2009 Electric Power Research Institute, Inc. All rights reserved. 4

Presenter: Don Osborne

© 2009 Electric Power Research Institute, Inc. All rights reserved. 5

 Proper alignment of turbine components is essential for good turbine

 Shaft misalignment also causes improper bearing loading.

 Bottom line, machinery misalignment is responsible for major expenditures in

© 2009 Electric Power Research Institute, Inc. All rights reserved. 6

© 2009 Electric Power Research Institute, Inc. All rights reserved. 7

• Section internal alignment is the vertical and horizontal relationship of the

© 2009 Electric Power Research Institute, Inc. All rights reserved. 8

© 2009 Electric Power Research Institute, Inc. All rights reserved. 9

 Review the as left alignment condition of the turbine-generator.

High radial loading Low radial load –

© 2009 Electric Power Research Institute, Inc. All rights reserved. 10

 Have all data sheets available for recording alignment measurements.

© 2009 Electric Power Research Institute, Inc. All rights reserved. 11

 Measure and record steam and oil seal radial clearances.

© 2009 Electric Power Research Institute, Inc. All rights reserved. 12

© 2009 Electric Power Research Institute, Inc. All rights reserved. 13

© 2009 Electric Power Research Institute, Inc. All rights reserved. 14

© 2009 Electric Power Research Institute, Inc. All rights reserved. 15

© 2009 Electric Power Research Institute, Inc. All rights reserved. 16

This information will aid you in making alignment correction decisions.

© 2009 Electric Power Research Institute, Inc. All rights reserved. 17

Indicator Mounted on Driver

© 2009 Electric Power Research Institute, Inc. All rights reserved. 18

 16 point coupling reading process:

© 2009 Electric Power Research Institute, Inc. All rights reserved. 19

© 2009 Electric Power Research Institute, Inc. All rights reserved. 20

 16 point coupling reading datasheet:

© 2009 Electric Power Research Institute, Inc. All rights reserved. 21

© 2009 Electric Power Research Institute, Inc. All rights reserved. 22

 Record clearance and compare to base line data.

© 2009 Electric Power Research Institute, Inc. All rights reserved. 23

© 2009 Electric Power Research Institute, Inc. All rights reserved. 24

 Data measured with dial indicators

© 2009 Electric Power Research Institute, Inc. All rights reserved. 25

 Inspect all the bearings in the turbine train:

Bearing assembled with improper tilt Bearing misalignment to journal. Tilt

© 2009 Electric Power Research Institute, Inc. All rights reserved. 26

© 2009 Electric Power Research Institute, Inc. All rights reserved. 27

© 2009 Electric Power Research Institute, Inc. All rights reserved. 28

 Visually inspect rotor journals and record any anomalies.

Grooves cut into shaft journals

© 2009 Electric Power Research Institute, Inc. All rights reserved. 29

© 2009 Electric Power Research Institute, Inc. All rights reserved. 30

 There is usually no need to measure the stationary component alignment prior to

© 2009 Electric Power Research Institute, Inc. All rights reserved. 31

 After evaluating the alignment data:

© 2009 Electric Power Research Institute, Inc. All rights reserved. 32

© 2009 Electric Power Research Institute, Inc. All rights reserved. 33

+ X = Right Horiz + Y = High Vert