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Alignment of Generator with Gear Box Coupling

06/19/2016 10:27 PM

Installation (Anchoring and Grouting) of SIEMENS SST-400 turbine (Turbine+ Gear Box+ Generator) has been completed. Final alignment of turbine coupling (flexible) with gear box has also been successfully finished.

But there is a mistake found before the final alignment of generator coupling with gear box coupling. This coupling is rigid (not flexible) and the Gap between generator and gearbox coupling is 31 mm instead of 17mm. The difference of 14mm is very huge as the STG is very precise equipment. All the installed pipelines for Oil and cooling water as well as bus-bar have been completed with generator and gearbox, these will have to be dismantled, generator shall be re-lifted and auxiliary system will have to be erected again. These additional works are very time-consuming and costive.

I need purely technical suggestions to solve this problem. Whether there is solution of this problem without disturbing the auxiliaries’ work, if it is then please share. Or either will have to dismantle all and perform the levelling again?

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#1

Re: Alignment of Generator with Gear Box Coupling

06/19/2016 10:51 PM

Here is the only purely technical suggestion you will get here (from me).

Your only hope is to enlist the help of the factory.

NO OTHER solution will save you if the makeshift coupling you install fails.

Do it right the first time, or do it right the second time, but DO IT RIGHT or you will have no factory support WHEN, not if, it fails.

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#2

Re: Alignment of Generator with Gear Box Coupling

06/20/2016 12:39 AM

Maybe you could get a custom made coupling, but that might cost as much and take as much time just to redo it correctly....

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#3

Re: Alignment of Generator with Gear Box Coupling

06/20/2016 1:08 AM

The hold-down bolts are likely larger than 14mm diameter, so moving any one item may result in overlapping bolt holes, which is untenable.

Your most hopeful option is probably a modified gearbox-generator coupling. This may necessitate collaborative engineering among the generator, gearbox, and coupling manufacturers. Overhung loads, vibration analysis, etc.

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#4

Re: Alignment of Generator with Gear Box Coupling

06/20/2016 4:26 AM

Do let the forum know how the phone call with the original equipment manufacturer went.

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#5

Re: Alignment of Generator with Gear Box Coupling

06/20/2016 3:03 PM

Assuming that the coupling faces are in perfect alignment but uniformly 14mm apart, the manufacturer may offer to fabricate a circular filler plate with the proper fit and finish to mate with the existing flanges and bolt holes, then spin test and balance it prior to installation. You could fabricate such a piece on your own, but doing so without the factory's approval will void the warranty for all equipment connected to it.

Quite frankly, you screwed up once so why would the factory trust you to do it right the second time; therefore follow Lyn's advice.

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#6

Re: Alignment of Generator with Gear Box Coupling

06/20/2016 3:33 PM

Are you the project engineer or the inspector trying to Cover Your A$$? Somebody screwed up substantially, and that someone should be let go off the job. As Lyn said, contact the manufacture and as RamConsult's suggested, maybe a filler plate,. But,you have to get the the manufacture involved for the warranties.

Please come back and let the forum know the outcome of the install.

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#7

Re: Alignment of Generator with Gear Box Coupling

06/21/2016 1:33 AM

14mm spacer may be placed between the couplings to make up for the increase in gap.

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dj95401 (1); IRSHAD (1); lyn (1); PWSlack (1); RAMConsult (1); SolarEagle (1); Tornado (1)

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