On-Site Machining: Power Plant Project List

power station

When you consider the demands that turbine components in power plants are exposed to, it comes as no surprise that eventually many components will wear out and operate less efficiently. With steam turbine temperatures being of over 500°C, pressures of 4000psi and components rotating at speeds of over 3000rpm, the importance of a well-managed and robust maintenance programme cannot be overstated. 

What are the potential problems?

With turbines, the danger signals to watch out for include unusual vibration, noisy or unusually hot bearings, gland leakage, governor hunting, and lubrication problems such as low oil pressure, discoloured oil, or a broken lubricator.

Fixing the above can involve the use of portable machining tools and to help you select the right machine for your next project. Below, we’ve listed machining applications and matched these to the relevant machine type from the Mirage range.

View the table below, of if you prefer you can download a Pdf version here.

POWER PLANT MAINTENANCE PROJECTON-SITE MACHINE TO USE
BEARING PEDESTALS 
Machining the flat base of bearing pedestalsMilling Machine
Machining the inside diameter of bearing pedestalsSmall Line Boring Machine
TURBINE CASINGS 
Machining of surfaces in large diameter turbine casings (LP casing)Large Line Boring Machineor Mirage WB1500
Casing split line surfaces (steam turbines, LP, MP, HP)Milling Machine
Creating sealing groves on turbine casingsMilling Machine
Machining of internal grooves in turbine casingsFlange Facing Machine
Machining surfaces for glands in the turbine casingSmall Line Boring Machine
TURBINE BLADES 
Drill out turbine blade retainer pinsPD760 Pin Drill (bespoke product)
Cutting worn and damaged turbine blade tipsBLS760 Blade saw (bespoke product)
DIFFUSORS 
Machining valve chambers (diffusors)Small Line Boring Machine
Machining of large diffusorsLarge Line Boring Machine
Machining of valve chambers (upper surface)Flange Facing Machine
SHAFT MACHINING 
Turbine shaftMid Shaft Turning Machine
Generator ShaftMid Shaft Turning Machine
COUPLINGS AND HOLE BORING 
Wicket gate bearing hole boringLarge Line Boring Machine
Boring of generator couplingsLarge Line Boring Machine
Machining of coupling holesSmall Line Boring Machine
HEAT EXCHANGERS 
Face MachiningFlange Facing Machine
Back Face machiningFlange Facing machine (with Back Facing Kit)
Division Slot Machining2 axis milling machine
HYDRO PLANTS 
Machining of large turbine casings in hydro power plants (turbine face plate & seal ring machining)Large Line Boring Machine
Stay vane machining3 axis milling machine
Downhole repair (Machining turbine unit in-situ)Flange Facing Machine
DIAPHRAGMS 
Machining of the internal grooves for small diaphragmsSmall Line Boring Machine
Machining for diaphragmsFlange Facing Machine
PIPELINES 
Cutting pipesSplit Frame Clamshell Cutters
Pipe bevellingSplit Frame Clamshell Cutters
Counter-boringSplit Frame Clamshell Cutters
Flange removalSplit Frame Clamshell Cutters
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The above is just a selection of potential applications. If you need equipment for an on-site machining project get in touch with us here.

Discussion

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  1. Jon | September 15, 2020 | Reply

    Thank for the tips!