Hydro Power Plant Machining and Modernization
Comprehensive Turbine Repair and Outage Support at Hydro Power Plant in Oceania
Category: Hydroelectric Power Plant Field Machining
Method(s) Used: On-Site Machining and Customized Portable Equipment
Location: Australia
This hydroelectric generating plant was commissioned in 1977 and features three vertical shaft generator sets. Over the years, partial upgrades have been carried out during multiple outage seasons. In-Place Machining Company has provided comprehensive field machining services and outage support for several of these maintenance periods.
Project Documentation
On-site machining and dimensional checks of turbine runner assembly
Precision machining of cheek plates for turbine upgrade
On-site machining of turbine runner and shaft
Machining of turbine shaft on a customized rotary table
The Problem + Project Scope
An aging hydroelectric power plant, in operation for nearly 50 years, was experiencing chronic vibration issues while also facing increased demand for power output. To keep pace with these challenges, the facility required targeted upgrades and modernization. The project focused on repairing and improving key turbine components to restore reliability and meet performance expectations. The scope of work included the following:
- Precision Field Machining of Turbine Components: Stationary Wearing Ring, Turbine Shaft and Runner Assembly, Turbine Shaft Bearing, Turbine Coupling, Head Cover, and Stator Thrust Pad
- Customized portable equipment and engineered tooling
- Detailed dimensional verifications, inspections, and documentation
- Project Planning and Engineering Support
Challenges
- High precision technical requirements, including concentricity tolerance of .003” and 125 RMS finish
- Multiple inspection points and comprehensive technical documentation to ensure OEM specifications are met
- Customized fixturing and machining setups were required
- Fast turnaround time required with expedited mobilization and machining to be completed within the outage schedule
Solutions
- Rapidly mobilized a specialized team of expert field technicians, implementing a 24/7 shift schedule with day and night coverage to ensure project completion within the outage schedule
- Designed and engineered custom tooling and machining fixtures, tailored to accommodate complex geometries and challenging machining setups
- Performed high-precision field machining on turbine components, achieving exact dimensional specifications and surface finish
- Completed comprehensive dimensional and runout inspections, verifying that all turbine components were machined and installed in full compliance with technical and operational requirements
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