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New Power Generator required re-design of foundation

The Netherlands tel. +(31)180 48 43

By Tom Hoekstra

Project Re-Powering Project, replacement of 55 year old generatorClient Brush/HMA, Ridderkerk the Netherlands End user Electricity Power Plant in the HagueScope New Generator to be installed on ‘old’ foundation

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Brush/HMA- & Generator data

Brush/HMA 2 pole generator, water cooled

Capacity 27 Mw

Voltage 10.000V

RPM 3.000

Weight 50 ton

Driven by steam turbine (excisting)

Brush Turbogenerator Division manufactures 2- and 4-pole high voltage generators, synchronous motors and power management systems, with facilities in the UK, the Netherlands and the Czech Republic.

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Situation after removal of the old generator

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Old generator put aside after 55 years of service

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Based on the original drawings, the generator should fit in here…

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Taking down the old cast iron frame

Some parts did not give in that easy….

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3D laser measurement - step 1

A Sokkia totalsystem is used to measure the existing situation in relation to the Centre Line of the steam-turbine and coupling

Laser reference points are positioned in the area eshtablishing a 3D ‘space’

Within this space the exact position of the coupling and cavity are recorded, all within 0.1mm accuracy

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3D results ‘layed over’ the concept drawing

Points X,Y,Z related to -O- point set on coupling CL

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Physical CL’s are tightened for days the laser is not available

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Special, heavy consoles were designed

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Thorough calculations resulted in 4 consoles each one to be anchored with 4 pcs M36x765 bolts

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Anchor-calculation

Approved

Elongation is increased with a 100

mm spherical bush

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Anchorpockets and jackplates are set by means of a template

The drilled 12 mm holes indicate the centre-points of pockets and jackplates

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More accurate cutting with diamond drills

Due to the length, (∅100-L500) and instability of the drill it is impossible to get it centered precisely

For this reason we made a small assisting plate and pin

Steps:

Put pin in 12 mm holeSlide plate over pinPosition diamond drill over plateDrill 10 mm deepLift up the drill and remove plate and pinContinue drilling 0.5 mm less than

inside diam. of diamond teeth

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Then it is easy going!

4 of the holes to be drilled correspond with the old square pockets

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Jackplates

A ∅12 pin was welded underneath the jackplates, preventing them to move, then fixed to the concrete with Phillybond #6 and levelled

On the edge of the void an extra support bracket was mounted for safety

Each console weights 600 kg set on just 4 jackscrews

Data sheet PH6

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3D measurement - step 2

Each console is levelled with a spiritlevel (0.02/1000) and positioned within 0.1 mm accuracy by means of the Sokkia 3D (‘Geo-’)laser

The centrepoints (X,Y,Z) of 2 M36 threaded holes were set ≤ 0.1mm

To point out the centre of each hole, a M36 stub with sharp tip was used

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All measurements were set according to the footprint & CL drawing

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Grouting of the M36 anchors with Chockfast Red®

In the meantime the wooden + metal shuttering is mounted

The old pockets run through the angled foundation and needed to be closed with wood

Jackbolts and anchors are covered with armaflex and tape to avoid adhesion of the grout

Data sheet Chockfast Red

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Consoles aligned, grouted and anchored

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With the floor repaired, the cavity is waiting for the generator

Will it fit?

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Yes it does, exactly as intended

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Equally divided after the precision-alignment

2mm3mm

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More than enough precision-alignment space around the bolts

front back

M36 bolts tensioned

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Coolers on top and sound enclosure being mounted

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Coupling in place, piping attached

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Finally 2 dowel-pins are drilled and fitted

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We at EMHA like to express our thanks to the staff members of Brush/HMA for their kind cooperation to make

this job a succes!