~

_ 2 _

as a whole, it will be interesting to consider the troubles

that have had to be faced over the past thirty years with

this class of equipment.

Operating Troubles

Breakage of generator shafts has not been uncommon.

This usually occurs in the recess provided for the circular key

which secures the thrust collar, and is attributable to one or

a combination of the following:

(a) "loose fit" of the shaft in the thrust collar

(b) rubbing surface of thrust runner plate out~of-normal withspinning axis

(c) lack of fillets in the circular keyway itself,

The remedies to be applied are, in the same order,

provision of "tight fit" thrust collar, accurate construction

and alignment of thrust assembly and shaft, and provision of

fillets in the circular keyway. It is the author's experience

that shaft breakage does not result from lack of fillets in

the keyway or from out-of~normal relationship between runner

plate and axis, provided that the thrust collar is a tight fit

on the shaft, or is made a tight fit before fatigue cracks

become visible in the recess.

Attainment of a tight fit in some existing installa-

tions, without going to the expense and delay entailed in the

furnishing of a new collar, has proved a stumbling block in_

the p&Stw It may be of interest to you therefore to learn

that the Gntario Hydro adopted a few years ago, with completeI

/, '2,

_ 3 _

success, the nickel plating process as a means of reducing

the bore diameter of cast iron thrust collars.

\ Failures or so-called "near failures“* of thrust

bearings are likewisemnot uncommon in the vertical machine.

It is remarkable indeed to find - and this has been noted in

many and widely separated instances - that a thrust bearing

will operate for a number of years under the poorest condi-

tions of assembly and alignment. After ten years however

failure may be expected - this as a result of fatiguing, or

wiping, of the babbitt liners. on the other hand, properly

assembled and intelligently maintained bearings will have a

life approaching 25 years.

_ Failure of generator guide bearings is not a major

problem, When it occurs it is usually attributable to mis-

alignment or, in the case of the lower bearing, to unneces-

sarily small running clearance.

Wear and abnormal adjustment of lignum vitae turbine

bearings are among the most common troubles experienced, and

in many cases this is associated with excessive wear on the

shaft Journal in the form of tapers, flats and eccentrics.

These particular phenomena are attributable to misalignment and

unbalance in the rotating parts and, to some extent, impurities

in the "lubricating" water. The modern oil lubricated babbitted

bearing is the general solution to this problem, although some

*See A.I.E.E. Technical Paper 47-120, April 1947 IRobertson and Standing -"The Maintenance of Hydro-Electric Generating Units"

_i-

engineers today are slightly reluctant to make the change in

the somewhat rare case where the unit must operate seasonally

against abnormal back pressure occasioned by high tailwater '

due to ice jams. Since, however, it will not likely prove

feasible to convert the greater percentage of existing instal-

lations, the best that can be done in most cases is to attend

to the alignment of the shafts and bearing and balancing of

the runner, and to true-up the Journal periodically either

by a turning rig set up in place or by the more accurate and

admittedly expensive method of dismantling the shaft and doing

the job in the lathe»

Associated with the wear on the turbine shaft Journal

is that caused by packing in the bearing gland. Some success

has been claimed for various types of packings but the aim

should be towards doing away with them entirely, As a matter

of fact, the Ontario Hydro has one large plant operating under

235 ft. head in which just that was done. The replacement con-

sisted in a single copper ring machined to a knife edge at the

bore and fitted to the shaft with O",OO8 total clearance. The

amount of leakage to be handled will of course decide if this

is feasible, and in this regard a survey should be made to

determine the cause of the leakage if excessive.

Wear and corrosion of turbine guide vane stems is

another trouble to which the turbine of yesterday has been par-

ticularly susceptible. The answer to this lies in cladding the

stems with stainless steel, preferably in the form of sleeves

I

..5..

at the short end and welded (or sprayed) construction at the

long end. Today's turbine can be and usually is furnished

with this betterment. with regard to vane stem packings, very

satisfactory results have been obtained with asbestos braided

rubber core packings specially developed for this application.

Finally, we have the comparatively rare but extremely

costly occurrence of the turbine runner scrubbing and "galling"

on its seals. This situation is ascribed in some cases to

lack of sufficient running clearance, but more generally to

distortion and poor assembly or alignment of the component

parts of the turbine. The cure lies in providing ample and

reasonable clearances on the one hand and accurate checking

and alignment on the other.

Heguirements for Dependable Operation

From the foregoing it will be clear, in the author's

opinion at least, that two main requirements must be met in

manufacturing ani installing the vertical unit before it can

be depended upon to give-the service expected of it. These

requirements are: first, the thrust tearing must be manufac-

tured and assembled with precision and ‘he collar must be a

"tight fit" on the shaft; second, the stationary and rotating

parts must be aligned and centred with each other, and to'a

common vertical axis within the closest possible tolerances

permitted by practical considerations.

y This being the case, it remains to be explained how

these requirements are met. It is proposed therefore to dis-

-5-

Cuss the method used by Ontario Hydro and now accepted by

the manufacturers‘ erectors in our recent installations.

Before proceeding with this assignment, it will be

enlightening to review the method in general use heretofore,

which, for our purposes, may be referred to as the "old"

method.I

The Old Method of Erection - Fig. l

omitting the unnecessary details, the old method _

consists in placing and levelling the foundation ring and the

speed ring. The steel scroll case, if any, is affixed, the

whol~ then braced and "concreted in", when the concrete has

set turbine erection proceeds, but at this point no checks

are made, or in any case no action taken insofar as the author

is iware, with regard to the fact that the foundation and speed

rings may be distorted as a result of the concreting operations

So the shaft and runner are fastened together and dropped in

place and the guide vanes and headcover installed. The aim

now is to adjust all the parts such that the shaft is plumb

and properly positioned in elevation, the runner clearances

equalized, the shaft Journal centred in the bearing housing

and the guide vanes work freely. This accomplished, the re-

maining parts are affixed, fastenings made and the whole turned

over to the generator erector, with the understanding that the

shaft is plumb and truly centred and that the coupling flange

lies in a horizontal plane at a stated elevation. In perhaps

I

_ 7 _

the majority of cases this situation has proven acceptable

as a practical consideration, However, if the surfaces of

the component parts are seriously warped, out-of-round, or

otherwise distorted, and the shaft not properly plumbed, the

machine will not likely operate satisfactorily,

Erection of the generator, Fig” l, commences by

positioning the frame. This includes centring it to the

turbine coupling flange by aid of a plumb line, adjusting its

elevation, checking the bore for roundness and, of course,

levelling. The bearing brackets are also placed by aid of

the plumb line and the upper bracket at least is now perma-

nently referenced by dowelling, since it has no be removed.

(Spigot fits, where provided are not usually sufficiently accur-

ate) The work proceeds to a point where the rotor is in place

and suspended from the thrust bearing and the upper guide bear-

ing is in place. At this point adjustments are made to bring

the generator coupling flange into a plane parallel to that of

the turbine coupling flange and to make the flanges co-axialv

As a check on the accuracy of this adjustment the rotor is gen-

erally revolved 180 degrees and the situation re-examined; For

a number of reasons, the individual and :ollective alignment may

not be good and we may get a condition depicted in Fig, 2 when

the two machines are coupled together; Here we note that the

shaft in its effort to hang plumb is hard over on the guide

bearings and the runner about to scrub on its seals while the

whole weight of the rotating parts is localized on the circular

key at the high side of the thrust collar, whose runner plate

Ti

‘\1- -8-

surface has had to be thrown off the horizontal plane in order

to match the flange of tte inclined turbine shaft, This local-

izing of the weight around the circular key is just what is‘

needed in combination with the loose thrust collar to set up

fatigue stresses and lead to ultimate fracture of the shaft at

the circular keyway. The condition also produces uneven loading

and wear of the thrust bearing, fretting between the collar

and runner plate, and contributes to the likelihood of early

failure. Moreover, in the situation pictured, the machine

will probably display a dangerous "throw“ in operation and it

will be fortunate indeed if it does not come to grief through»

fouling of the runner seals.

Defects of the Old Method

The main trouble with the old method is that it takes

too much for granted. In machines of the size and complexity

of the vertical waterwheel-generator, it cannot be expected

that the parts will go together like a watch, therefore they

must be meticulously assembled, aligned and checked. It is

the ability of these machines to make a passable showing no

matter how poorly put together that more than anything has led

engineers and erectors into the easy attitude of "Oh, that's

good enough," and the comfortable feeling that "settlement of

foundations“ will explain everything when, someday, the machine

grinds itself to a stop. Many now agree that it is not good

enough and that, on the contrary, only a machine erected with

painstaking care is good enough.

¥' /

f1 _A9 _

Improvements in Manufacture J

1 In the effort to improve the construction and per-

formance of this class of equipment, manufacturers have co~

operated very agreeably to the end that many worthwhile bet—

,been made. Notable among these is the accurately.3. $11 <1 Dterments -

machined and finely finished thrust assembly with the “tight

fit“ collar, and, in the case of the spring supported bearing,

with spring units uniformly pre-loaded and sized as to length.

The advantages of this construction are that a generator so

equipped lends itself to accurate alignment and long service

and will not fail through fracture of the shaft in the cir-

cular key recess,

§ew;Method of Alignment

The method employed by the Ontario Hydro has its

beginning deep down in the stationary parts of the turbine, I

Assuming that ix is an initial installation, the foundation

ani speed rings are levelled as in the old method but the,

similarity disappears here. When the concrete has been placed

and is net, the two rings are again checked for level, If

fuuhi off-level more than some é mil per foot of diameter,

the re-5 0 Uthe surfaces are scraped, ground or machined to ~ -

Quirements, The lower distributor or cheek ring is now placed

and fastened, eight guide vanes placed in'4 groups of 2 ad-

jacent vanes equi-spaced, and the headcover lowered into positio

A plumb line is suspended from a suitable support at generator

floor level so that micrometer traverses may be made from it to

H.

._1@_

the lowest level of the unit, as indicated in Fig. SL This

plumb line is centred in the lower distributor ring by micro-

'1 §.J< ‘J CH +-- mmeter measurements, but should it be found that the

out-of-round, further progress is held up until the ring is

made round within satisfactory limits. when this has been

settled and the plumb line re-centred, the centre so chosen

becomes the one and only centre employed throughout the

erection of the unit. Since the line will have to be dis-

mantled from time to time, its position is referenced, Refer-

encing is done at two strategic planes, one where the shaft

emerges in the clear above the turbine bearing cover, and the

other absutl? feet above the coupling flange. Four equi-spaced

plugs at common elevation are set in the pit liner or in the

concrete wall as the case may be at each plane, and micrometer

readinfs are taxen from the plugs to the plumb line, The in-

formation obtained is sufficient to re-establish the line at

will.

To proceed with the alignment of the turbine: we have

the working surfaces of the foundation and speed rings made level

the lower distributor ring fastened in place and its bore sat-

isfactorily true and round and the plumb line in place and

centred to this bore, The object now is to bring the headcover

and bearing extension into line, to bring the upper and lower

guide vane stem bushings into line, and to see that the guide

vanes have proper working clearance between the upper and lower

surfaces in which they are confined. The adjustments to be made

_.1]_..

may include,grinding the runner seals in the headcover to

attain the desired degree of roundness, shifting the bearing

extension to bring it to centre and grinding the speed ring

to permit free guide vane swing. A mandrel simulating the

guide vane stems is employed to test the alignment of the

open stem positions. when these details have been attended to,

the headcover and bearing extension (if necessary) are sub-

stantially dowelled. The parts may now be dismantled in the

safe expectation that they will retain their alignment upon re-

assembly,

In the next step the plumb line is dismantled, the

headcover assembly removed, the shaft and runner put in place,

all the guide vanes installed and the headcover restored, Fig. #.

The tests to be carried out here consist in: centrlng the r" r

in the lower distributor ring and plumbing the shaft as acc

as this can be done by means of a sensitive level on the coupling

flange, thence checking the centring and clearances at the upper

runner seals and the centring at the bearing housing. If clear-

ances are inadequate or unequal, corrections will have to be

made to suit the occasion. when all is in order the bearing is. --._, _,,. .

placed, checked and adjusted according to type. The remaining

parts of the turbine may now be assembled and, finally, the job

is turned over to the generator erector,

The starting point of generator assembly lies in the

four plumb line reference plugs located above the coupling, Figo

The plumb line is re-established from these, making use of the

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rotating parts_are first given a fuliktgrn to assure a uhiformU“ VVfl@.

thickness of lbbricant at the thrust runner p1ate,~ Since ad~~ H§§". s t v -‘, _.1'.- > V >i.,

‘ " ¢ K .3 5

justmentsfiat the thrust bearing have sq far beenwefibroximate, eqéi_ :; .- . . - .35.

‘ ' V V . 1...»

it will probably be hecessary to make a finer adjustment here ~;% ,§§§' > - ~.-K‘ ~ ' '. - / ' -' - . —.'='..-.4:/.-~.

mito_assure@against£the runner fouling the>seals._ This done, ’ e%%%

the shaft 1sV§ecuratelytcentred in the ufiper gu£q§§§nd mipro¢ - gsfi

meter readings teken to the shaft in fohr diréotidns atttheb ‘§;f

turbine bearifig,hous1fig. The sha£t_1s rotated 180 degrees and Ai_@%‘ V ~ ‘. . .ms*the measuremeggs repeated. If the_meBsp;ementst@grge, the. V V .V§§$@

shafts are ooégkial and normal to the plahe~of'the robbing sur- .;%;§§

face of the thrust runner plate and all thgt»need be done is to t~.,e

edjust the thrust bearing (or the upper bracket) to§bring,the o» JV..._ .} .. . V ». ‘ .-

shaft;qentral in the turbine (since by plumb line hethod of l ii»- _ 1. .‘ »

ereotion the upper guide bearihg has already been gentred to the ;;§;%§. I V 7- - _ V , \ ‘_ .._ »-1 "k A

turbine bearing). However, it is hora likely that the turbine V .

shaftwilldescribe a cone dfirihg rotation, Fig. Glhffibis can A €.?f€

be ascribed to either a bent or kinged shaft or, more 11ke1y@Q §§¥g§§Q

to the shaft axis beihg of§;§orma1 to the pla§e;§§*§he.tpfu8th 'jf”gg§§.. .-H-/. ‘ V .;. . ,. ,_..

’ " ' ' "“ '5“ V ' ‘ ~V9 -(‘L . ‘ a<:|Ylq£ e‘ ~..‘ ;" yr ‘t; ‘ - V» . V~ ~“ ' ,.s¢.y:~@runner plate.’ Commod’causesg§$;the latter condition are;~cir~.;4;“@»&:. V- .»»h.e~. . .. »-- V &*.g%%*(- I i 7"’? ;r".*"’\ ' '- . >. . M "- . ‘ . " 14.. 3*“ 1' If "§@.V '*>"‘§,

.cu1ar key non-uniform as toéfibfitknéss, top and bottom surfaces"§§”?;§%§V 1' .~\ _ V V - . V Viv,‘ ;..£~,.:_

'- '- 1 ‘ ..r- - \ . .

of thrust collar ogt+¢r;pérax1e1 or either or both oqt-of-nor; J4 §n“§

mal with the ‘beige, we;1211; of" thrust caller, be5Li>s,;i;.,..V_runner place non-uniform.as%§% thickness anfi, in~z&§ céseybfhier &fi§%

spring,supported bearings, insulation between thrust collar and%§§§3%§iV‘ 1. V " . 1 . . ,. V . V .1 V-f if

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may also give rise to this condition. All of these situations

are to be looked for in the older installations, but in the‘wk . .

present day machine are not common, with the exception of the

one attributed ta insuletion.- It appears that this material

is not yet available ephercially to meet the desired close

tolerance in thicgness,*t 1

Exampleaaare given in Fig. 8 depicting several of_ , _

the causes of shaft "run-out"; the corrective measures to be

‘taken are obvious, ‘Good practice indicates that the radius

of eccentricity described by the shaft at any point should

not exceed % mil.mu1tiplied by the distance in feet measured

from the point to the plane of the thrust bearing rubbing- . n- \rsurface and, by the*same token, the shaft should not be out-

of—plumb at any point in excess of the same amountg It should

be added, however, that the Ontario Hydro endeavours to limit\‘ '~

‘the error to half this amount, and usually succeedsa

In any event, when the 7cone of rotation" at the

turbine has been reduced to an acceptable degree of accuracy\ ,

within the practical limit mentioned, it remains to centre

this cone in the turbine bearing, and this may be done by

plumbing adjustment at the thrust bearing, and, should but a_

few thousandths be needed, by moving the upper guide bearing

bodily, When finished the turbine shaft should be positioned

and held dead-centre in the turbine whilst the lower generator

bearing is placed and checked, and adjusted if necessary to

give uniform clearance, see Fig, 7, ‘ V

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