Vertical Turbine Bearing Alignment

A Case Study using the CENTRALIGN Ultra system and the LEVALIGN Laser.
A contractor from Spokane requested a bore centerline alignment of a vertical hydro turbine in
northern Idaho. After receiving more detailed information and visiting the site, it was
determined that this task would be possible using a combination of the CENTRALIGN ULTRA
STANDARD (a bore laser alignment system) and the LEVALIGN laser (a laser for flatness and
squareness measurement).
The setup of the equipment was straightforward. The LEVALIGN laser was placed on a sturdy
steel plate attached just below the bottom bore (lower thrust bearing) as shown in Figures 1
and 2 below.

Figures 1 & 2

The LEVALIGN laser was carefully plumbed using its integrated the leveling vials and aimed
vertically through the bore of the turbine. The laser was aimed so that it passed through the
approximate the center of the bores using a tape measure as a guide. This rough alignment of
the laser beam is all that is necessary because CENTRALIGN does not require exact

2012 LUDECA Inc. www.ludeca.com

centering of the laser from the bottom bearing to the top bearing. This makes setup quick and
easy. CENTRALIGN determines the precise position of the bore center with respect to the
laser. From this information, the software can optimize the results through any combination of
desired fixed points, or the user can view the raw data as the deviation of each measured bore
center from the laser line or the deviation of any bore with respect to a reference line between
its two adjacent bores (the Differential view.)
Each bearing bore was measured using the CENTRALIGN pointer bracket system in
combination with the standard shaft alignment magnetic brackets shown in Figure 3.
CENTRALIGN features automatic vibration compensation for the laser to eliminate the effects
of vibration. This is particularly useful when adjacent turbines are in operation.

Figure 3

The rotating single point contact plunger, used for measuring the bores, allows CENTRALIGN
to determine the precise position of the bore center with respect to the laser beam. Out-ofroundness of the bore is measured as well. CENTRALIGN offers the user four measurement
quality factors that can influence the accuracy of the readings: Number of Points taken, Spread
of the Points, Total Angle of Readings (first point to last point), and Standard Deviation of the
measurements. The program then analyzes all four quality factors to provide an overall quality
factor for the readings as shown in Figure 4. Stray or rogue points can be toggled off from any
reading for an even more accurate calculation of the true center of the bore.

2012 LUDECA Inc. www.ludeca.com

Figure 4

The out-of-roundness information obtained is extremely useful as well. For instance, when
machining a thin walled bore, such as the Upper Guide Bearing, it is extremely difficult to
machine without warping the bore, making it egg shaped.
Figure 5 shows that the point taken at the 315 degree position had the highest deviation of
2.170 mils. With this point active, the total (overall) quality of the readings was only in the
green (acceptable) range, at a quality factor of 0.74.

Figure 5

Figure 6 shows that when the 315 degree point was toggled off from the calculation, the
Standard Deviation decreased from 0.85 mils to 0.27 mils, improving the total quality factor to
0.86, thus bringing it into the blue (excellent) range shown in Figure 7.

2012 LUDECA Inc. www.ludeca.com

Figure 6

Figure 7

Figure 8 shows the results screen with the deviation from the reference laser line. This gives
an indication of how far out of plumb each bearing is from gravity. The difference from top to
bottom was only 8.09 mils over a total distance of 408" (34 feet) giving a tilt from top to bottom
of 0.238 mils per foot. NEMA tolerance is 0.25 mils per foot.

2012 LUDECA Inc. www.ludeca.com

Figure 8

When optimizing the bores to the reference laser line, the intermediate bearing shows the
largest deviation of 2.62 mils as shown in Figure 9.

Figure 9

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When the lower and upper bearings are fixed, the results display the deviation from a straight
line between these two fixed points, replicating a tight-wire between the centers of the lower
and upper bearings, as shown in Figure 10 below.

Figure 10

In conclusion, both the plumbness and alignment measurements were completed in a fraction
of the time they would have taken by means of the traditional tight-wire method. CENTRALIGN
ULTRA provided highly accurate and repeatable user-independent results. A fully detailed
graphical report was instantly generated on site and saved to a USB flash drive in PDF format.
This was given to the contractor for their records.
Roy Loop with The Rueck Company is the Idaho representative for LUDECA, Inc., a leading provider of shaft
alignment, vibration analysis and balancing equipment. Roy has over 20 years experience in the field of Shaft
Alignment. He can be reached at roy@rueckco.com or 503-644-8363.

2012 LUDECA Inc. www.ludeca.com