Retrofit | Allis Chalmers
TurbinePROs field services provided site supervision and all craft labor for this hydroelectric retrofit project. Unit centerline established from the draft tube just below the discharge ring (670’ elevation), up to just above the stator/rotor assembly (726’ elevation). Once reassembled, it was plumbed to within .00025” per foot of effective shaft length, or .0088” from the centerline of the generator guide bearing to the centerline of the turbine guide bearing (425”).
In addition to these services, TurbinePROs also refurbished most components- large and small- to some extent depending on the component, including: dimensional inspections of machined surfaces, bearing surfaces, bearings, journals, pins, coupling studs, coupling bores, and shafts.
Hydro
Allis Chalmers Hydro Turbine Kaplan Runners replaced with Fuji
84 MW per /10 Units
Details
Rotor
Removed 889,332lb-Unit 4 rotor that was skewed on the rim, stripped the rotor poles, unstacked the rotor laminations, set the rotor spider back to its proper working condition, restack laminations, torque 504 rim bolts, reinstall the torque and shrink keys
stator
Removed 363,992 Lbs. (assembled) stator from powerhouse and scrapped. Removed embedded sole plates from foundation. Installed new sole plates, new stator frame, and 178,000 Lbs. of laminations (supplied by Toshiba)
Generator shaft
139,000 Lbs. Removed and Cleaned
lower bearing bracket
175,000 Lbs. Removed, cleaned, and transported from powerhouse to blast building for lead abatement and new coating. Returned to powerhouse.
Turbine Shaft 135,000 Lbs.
Removed from powerhouse, tipped to horizontal position, set in cradles, and loaded onto rail car for transportation to machine shop for modifications, reinstalled.
Runner (kaplan type)
367,000 Lbs.- Runner removed with the inner and intermediate head covers form the unit, the inner head cover and intermediate head covers set on a trailer, the lower cone is then removed, the runner is then set on an assembly/ disassembly pedestal, the runner is then turned over in a special build fixture to allow for disassembly of the inner workings and blade removal (Combined weight at the start of this pick, including the lifting beam is 428,300 Lbs.)
Outer head cover (96,000 Lbs.)
The outer head cover was raised and set on top of the gate stems, separated into 4 pieces and flown out of the turbine pit. The outer head cover is to large diametrically to remove in one piece.
rigging up to 889,000 lbs.
wicket gates (x20)
(190,000 Lbs. combined… 9,500 Lbs. each). The wicket gates removed from the unit, one at a time.
Balance of Plant Systems- installed
High pressure greasing system
-Air and water supply lines in and out of the unit
-Brake air and Jacking hydraulic lines
-Dust collection system around unit’s 8 brakes
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Unique Project Challenges
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