The document summarizes a project to replace an old power generator at an electricity power plant in The Hague, Netherlands. A new 27MW generator from Brush/HMA required redesigning the old foundation. Laser scanning and 3D modeling were used to precisely measure and design concrete consoles to support the 50 ton generator in the same location as the old one. The consoles were installed, grouted in place, and the generator was successfully installed within the precision tolerances required.

1. New Power Generator required re-design of foundation
Project Re-Powering Project, replacement of 55 year old generator
Client Brush/HMA, Ridderkerk the Netherlands
End user Electricity Power Plant in the Hague
Scope New Generator to be installed on ‘old’ foundation
The Netherlands tel. +(31)180 48 43
By Tom Hoekstra
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2. Brush/HMA- & Generator data
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.
Brush/HMA 2 pole generator, water cooled
Capacity 27 Mw
Voltage 10.000V
RPM 3.000
Weight 50 ton
Driven by steam turbine (excisting)
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3. Situation after removal of the old generator
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4. Old generator put aside after 55 years of service
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5. Based on the original drawings,
the generator should fit in here…
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6. Taking down the old cast iron frame
Some parts did not give in that easy….
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7. 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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8. 3D results ‘layed over’ the concept drawing
Points X,Y,Z related to -O- point set
on coupling CL
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9. Physical CL’s are tightened for days
the laser is not available
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10. Special, heavy consoles were designed
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11. Thorough calculations resulted in 4 consoles
each one to be anchored with 4 pcs M36x765 bolts
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12. Anchor-calculation
ed
Approv
Elongation is
increased
with a 100
mm spherical
bush
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13. 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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14. 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 hole
Slide plate over pin
Position diamond drill over plate
Drill 10 mm deep
Lift up the drill and remove plate and pin
Continue drilling
0.5 mm less than
inside diam. of
diamond teeth
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15. Then it is easy going!
4 of the holes to
be drilled
correspond with
the old square
pockets
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16. Jackplates
A ∅12 pin was welded underneath the jackplates, preventing them to move, then fixed to the concrete
with Phillybond #6 and levelled Data sheet PH6
On the edge of the void an
extra support bracket was
mounted for safety
Each console weights 600 kg
set on just 4 jackscrews
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17. 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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18. All measurements were set
according to the footprint & CL drawing
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19. Grouting of the M36 anchors with Chockfast Red®
In the meantime the wooden + metal shuttering is mounted Data sheet Chockfast Red
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
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20. Consoles aligned, grouted and anchored
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21. With the floor repaired,
the cavity is waiting for the generator
Will it fit?
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22. Yes it does, exactly as intended
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23. Equally divided after the precision-alignment
3mm 2mm
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24. More than enough precision-alignment space
around the bolts
front back
M36 bolts tensioned
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25. Coolers on top and sound enclosure being mounted
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26. Coupling in place, piping attached
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27. Finally 2 dowel-pins are drilled and fitted
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28. 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!
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