When it comes to keeping power generation facilities running efficiently, alignment accuracy is critical. While our colleagues at OASIS Alignment Services specialize in laser tracker-based alignment inspections, Exact Metrology supports these efforts with advanced 3D scanning and long-range scanning. By capturing high-resolution data and creating detailed digital models, we help engineers reverse engineer legacy components, validate alignment, and perform virtual fit-ups before outages.
In traditional power generation – coal, gas, nuclear, & hydropower – the performance and reliability of critical equipment hinge on precision alignment. Turbines, generators, pumps, compressors, and other rotating assets operate under immense loads and at high speeds. Even a misalignment of a few thousandths of an inch can introduce excessive vibration, increase shaft loading, shorten bearing life, and elevate energy consumption—often leading to forced outages and costly downtime.
Why Alignment Matters
Industry studies estimate that nearly 50% of rotating equipment failures are directly related to misalignment. For power plants that operate continuously, the consequences of a minor deviation are magnified across millions of operating cycles. Misalignment increases heat generation, accelerates seal wear, and places uneven stress on couplings and supports. Precision alignment reduces mean time between failures (MTBF) and ensures equipment operates within OEM-specified tolerances, supporting both safety and regulatory compliance.
Laser Trackers Capture Precise Data Quickly, Even in Harsh or Hard-to-Reach Environments
Laser Trackers Take the Lead in Precision Alignment
Alignment specialists today rely on laser tracker technology as the gold standard for precision measurement. Highly accurate, laser trackers deliver three-dimensional measurements over a range of 200 feet – with accuracy of ±0.001 inch (±25 microns) over a specified range.
Laser trackers measure shaft centerlines, coupling offsets, and machine casing positions in real time, allowing technicians to adjust components interactively. This reduces setup time, improves repeatability, and provides detailed digital documentation of as-found and as-left conditions. For critical machines like steam turbines and generators, this level of precision ensures components operate on a true common centerline—minimizing vibration and maximizing efficiency.
In addition to turbine-to-generator alignment, precision metrology also supports inspection of casings, keybars, stators, main bearings, and couplings. Services extend into gearboxes, clutches, pumps, and compressors—ensuring that the entire drive train and ancillary equipment operate as a cohesive system. By accounting for thermal growth, pipe strain effects, and foundation stability, technicians address not just the machine itself but the broader plant environment that influences long-term reliability.
Expanding the View with 3D and Long-Range Scanning
While laser trackers are the foundation of alignment inspections, complementary technologies expand the capability of plant maintenance teams. Structured-light and portable 3D scanners capture wear patterns on shafts, turbine runners, or pump housings with exceptional detail. Long-range laser scanners provide point clouds of entire plants—mapping penstocks, scroll cases, piping systems, generator decks, and discharge rings across multiple levels of a facility.
3D Point Cloud Data of Industrial Plant
This integration of large-scale and component-level data creates true digital twins of assets and assemblies. Engineers can conduct turbine runner clearance studies, evaluate wicket gate and stay ring alignment, or perform volumetric site scans for planning a turbine rebuild. Post-disassembly, rotor and wheel geometries can be captured and referenced for as-left validation, while surface scans detect cavitation damage in penstocks, draft tubes, or turbine blades.
Virtual Fit-Up and Reverse Engineering
With digital models in hand, power plants can take advantage of advanced applications that reduce outage risk. Virtual assemblies simulate the fit-up of new or refurbished components into the as-found plant model—exposing clearance issues or interferences before installation begins. For legacy equipment without OEM drawings, reverse engineering workflows transform scan data into CAD models, enabling accurate reproduction of shafts, casings, and other parts. Casting stock analyses and custom tooling designs further ensure new components are machined and installed with confidence.
CAD Mode of Hydropower Turbine
Benefits to the Power Industry
For the power generation sector, precision alignment combined with advanced metrology translates into measurable benefits:
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- Extended equipment life: Reduced bearing loads, improved seal performance, and minimized shaft fatigue.
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- Increased Efficiency: Proper alignment lowers parasitic energy losses, improving thermal cycle performance.
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- Reduced Outage Durations: Faster, more accurate alignment and pre-validated virtual assemblies shorten the critical path of maintenance.
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- Enhanced Safety: Fewer unexpected failures reduce the risk to maintenance teams and plant personnel.
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- Regulatory Confidence: Digital alignment reports and as-left documentation support compliance with industry standards such as ASME and IEEE.
When Misalignment Has Already Caused Damage
Even with precision alignment practices, operational stresses can cause wear or distortion. In these cases, in-place machining and shop-based repairs restore journals, thrust faces, bores, and other critical surfaces to original or improved tolerances—allowing for proper realignment and extending service life. When combined with advanced measurement data, machining solutions ensure components are returned to service with verified accuracy and reliability.
Exact Metrology is part of the Measurement & Alignment Division of In-Place Machining Company, and is proud to partner with OASIS and the full IPM family to provide comprehensive measurement and inspection solutions. Contact us today to learn how alignment and advanced scanning work together to maximize reliability in the power industry.
