{"id":8789,"date":"2017-05-02T16:36:28","date_gmt":"2017-05-02T20:36:28","guid":{"rendered":"https:\/\/www.mdaturbines.com\/?p=8789"},"modified":"2022-04-28T08:47:51","modified_gmt":"2022-04-28T12:47:51","slug":"dflp-rotor-straightening","status":"publish","type":"post","link":"https:\/\/www.mdaturbines.com\/resources\/dflp-rotor-straightening\/","title":{"rendered":"DFLP Rotor Straightening and Machining"},"content":{"rendered":"<p>Mechanical Dynamics &amp; Analysis was contracted to straighten and machine a double flow low pressure (DFLP) rotor from a 3,600 rpm, 103 MW combined cycle power generating unit. The rotor forging arrived with both shaft ends bent.<\/p>\n<p>The Turbine end shaft end was bent and found to have a 0.007\u201d total indicator runout (TIR) at the coupling outer diameter. The generator end shaft end was bent and found to have a 0.053\u201d TIR at the coupling outer diameter. MD&amp;A was able to straighten both shaft ends to within 0.0015\u201d TIR using a combination of thermal and machining straightening processes. Then, MD&amp;A completed the final high-speed balance and final machining of the shroud covers.<\/p>\n<figure id=\"attachment_8794\" aria-describedby=\"caption-attachment-8794\" style=\"width: 660px\" class=\"wp-caption aligncenter\"><a href=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig1Web.jpg\"><img decoding=\"async\" class=\"size-full wp-image-8794\" src=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig1Web.jpg\" alt=\"DFLP Rotor Straightening\" width=\"660\" height=\"440\" srcset=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig1Web.jpg 660w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig1Web-300x200.jpg 300w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig1Web-240x160.jpg 240w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig1Web-90x60.jpg 90w\" sizes=\"(max-width: 660px) 100vw, 660px\" \/><\/a><figcaption id=\"caption-attachment-8794\" class=\"wp-caption-text\">Rotor Forging After Removal of All Blades &amp; Seal Strips<\/figcaption><\/figure>\n<p><strong>Shaft End Thermal Straightening<br \/>\n<\/strong>The rotor thermal straightening process included an initial rotor stress relief and multiple thermal straightening iterations. MD&amp;A expert technicians performed detailed visual, dimensional, and non-destructive examination (NDE) of the rotor forging before and after each thermal process to confirm that no issues were present. Rotor NDE inspections consisted of both hardness testing and wet fluorescent magnetic particle testing.<\/p>\n<p>Based on the amount of shaft end distortion and the experience and expertise of MD&amp;A technicians, it was recommended carrying out an initial stress relief of the rotor and additional thermal straightening iterations of the shaft ends to further reduce the shaft end runouts.<\/p>\n<p><a href=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig2Web.jpg\"><img decoding=\"async\" class=\"aligncenter size-medium wp-image-8793\" src=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig2Web-300x200.jpg\" alt=\"DFLP Rotor Straightening\" width=\"300\" height=\"200\" srcset=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig2Web-300x200.jpg 300w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig2Web-240x160.jpg 240w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig2Web-90x60.jpg 90w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig2Web.jpg 660w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/a><\/p>\n<p>The initial stress relief of the rotor forging was performed on both shaft ends to relieve any internal stresses and determine the final relieved state of the shaft end runouts. This involved removing all installed blades and seal strips, stress relieving the rotor, blast cleaning, NDE, hardness checks, and runout checks along the length of the rotor.<\/p>\n<p>Additional thermal straightening iterations were also performed on the generator end of the shaft to further reduce the amount of runout. This involved thermally moving the shaft end, stress relieving the rotor, blast cleaning, NDE, hardness checks, and runout checks along the length of the rotor.<\/p>\n<p>Due to the high temperatures of both couplings during the stress relief processes, a vertical stress relief was not possible. As a result, the stress reliefs were performed in the horizontal orientation while rotating the rotor periodically 180\u00b0 during the heating process so as not to set a thermal bow into the rotor.<\/p>\n<p><a href=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig3Web.jpg\"><img decoding=\"async\" class=\"aligncenter size-full wp-image-8797\" src=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig3Web.jpg\" alt=\"DFLP Rotor Straightening\" width=\"660\" height=\"354\" srcset=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig3Web.jpg 660w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig3Web-300x161.jpg 300w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig3Web-298x160.jpg 298w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig3Web-90x48.jpg 90w\" sizes=\"(max-width: 660px) 100vw, 660px\" \/><\/a><\/p>\n<p><strong>DFLP Rotor Machining<br \/>\n<\/strong>Based on results of the thermal straightening iterations, machining straightening of both shafts was performed. The work involved final straightening machining of both shaft ends and final dimensional, NDE, and runout checks along the length of the rotor.<\/p>\n<p>The thermal straightening operations reduced the Turb End shaft end TIR from 0.007\u201d at incoming to 0.003\u201d after completion. The Turb End shaft end straightening machining included final machining of the steam gland diameter, all steam gland seal grooves, all transition radii, and the coupling to remove any remaining runout.<\/p>\n<p>The thermal straightening operations reduced the Gen End shaft end TIR from 0.053\u201d at incoming to 0.015\u201d after completion. The Gen End shaft end straightening machining included final machining of the journal, oil deflector, steam gland diameter, all steam gland seal grooves, all transition radii, and the coupling to remove any remaining runout. Also, the coupling holes were line bored to set the bolt circle pattern back on center.<\/p>\n<p><a href=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig4Web.jpg\"><img decoding=\"async\" class=\"aligncenter size-medium wp-image-8796\" src=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig4Web-300x200.jpg\" alt=\"DFLP Rotor Straightening\" width=\"300\" height=\"200\" srcset=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig4Web-300x200.jpg 300w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig4Web-240x160.jpg 240w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig4Web-90x60.jpg 90w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig4Web.jpg 660w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/a><\/p>\n<p><strong>High-Speed Balance<br \/>\n<\/strong>In parallel to the blading and seal strip installation, MD&amp;A produced a new stub shaft in support of performing the high-speed balance.<\/p>\n<p>The balance work involved the installation and aligning of the new stub shaft, installation of the rotor in the high-speed balance facility, balancing the rotor at operating speed, and performing an overspeed test of the rotor.<\/p>\n<p><a href=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig5Web.jpg\"><img decoding=\"async\" class=\"aligncenter size-medium wp-image-8795\" src=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig5Web-300x200.jpg\" alt=\"DFLP Rotor Straightening\" width=\"300\" height=\"200\" srcset=\"https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig5Web-300x200.jpg 300w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig5Web-240x160.jpg 240w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig5Web-90x60.jpg 90w, https:\/\/www.mdaturbines.com\/wp-content\/uploads\/2017\/05\/Fig5Web.jpg 660w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/a><\/p>\n<p>The rotor work was completed on schedule and returned to the owner.<\/p>\n<p>For every <a href=\"https:\/\/www.mdaturbines.com\/repairs\/gas-turbine\/\">repair<\/a> job, large or small, the speed and effectiveness of our response team is matched only by the depth and breadth of our engineering expertise.<\/p>\n<p><strong>Have us look at your bowed rotor today. Call our <a href=\"https:\/\/www.mdaturbines.com\/repairs\/steam-turbine\/\">Turbine-Generator Repair Facility<\/a> at (314) 880-3000 <\/strong><strong>or use our <a href=\"https:\/\/www.mdaturbines.com\/contact\/\">Contact form<\/a>.<\/strong><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Mechanical Dynamics &amp; Analysis was contracted to straighten and machine a double flow low pressure (DFLP) rotor from a 3,600 rpm, 103 MW combined cycle&#8230;<\/p>\n","protected":false},"author":2,"featured_media":8795,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"content-type":"","footnotes":""},"categories":[208,209],"tags":[142,144,86,141,143],"class_list":["post-8789","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-gas-turbine","category-steam-turbine","tag-dflp-rotor","tag-high-speed-balance","tag-parts-machining","tag-rotor-straightening","tag-stress-relief"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.9 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>DFLP Rotor Straightening and Machining &#8211; 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