PICTURE OF THE YEAR #3: Francis Hydroelectric Turbine Flange

07 Jan PICTURE OF THE YEAR #3: Francis Hydroelectric Turbine Flange

Martin Bachmann Keller EIRL, based in Lima, Peru, demonstrated exceptional work using a CLIMAX FF8200 Flange Facing Machine for a Francis Hydroelectric Turbine Flange Repair.

The Francis turbine, a reaction turbine, operates on principles of both impulse and reaction forces, converting water pressure and flow into mechanical energy to generate electricity. This project highlights the precision and expertise required for such critical repairs.

Remachining Francis hydroelectric turbine flanges in place is crucial for maintaining the efficiency, safety, and reliability of the turbine system. Here’s why this process is so important:

1. Ensuring Proper Alignment

• Importance: Francis turbines rely on precise alignment between the turbine, shaft, and generator to maintain efficient power generation and prevent mechanical issues.
• In-Place Machining Benefit: Remachining the flanges in their installed position ensures perfect alignment with the connected components, eliminating the risk of misalignment caused by transportation or reassembly.

2. Restoring Mating Surfaces

• Problem: Over time, flange surfaces can wear, corrode, or become uneven due to operational stresses, thermal cycles, or environmental conditions.
• Solution: Remachining restores the flatness and smoothness of the flanges, ensuring a secure, leak-proof seal between mating components, such as casing segments or pipe connections.

3. Minimizing Downtime

• Challenge: Removing the turbine for off-site repair is time-consuming and expensive, causing extended downtime.
• Advantage: In-place machining eliminates the need to disassemble and transport the turbine, reducing downtime and associated costs significantly.

4. Enhancing Operational Efficiency

• Impact of Worn Flanges: Uneven or damaged flanges can lead to misalignment of the turbine components, causing increased wear, vibration, and energy losses.
• Remachining Benefit: Ensures that all components fit perfectly, reducing mechanical stress and improving the overall efficiency of the turbine.

5. Preventing Leaks and Failures

• Risk: Damaged or uneven flanges can result in improper sealing, leading to water leaks or pressure losses.
• Solution: Precision re-machining creates a smooth and even surface that supports effective sealing, preventing leaks that could compromise the turbine’s performance or safety.

6. Maintaining Structural Integrity

• Issue: Corrosion, thermal cycling, and operational stresses can weaken the flange over time.
• Benefit: Remachining removes damaged material and restores the flange’s structural integrity, preventing cracks or failures under operational pressure.

7. Adhering to OEM Specifications

• Requirement: Turbines must operate within precise tolerances to meet performance and safety standards.
• Outcome: In-place machining ensures the flange meets or exceeds OEM specifications, maintaining compliance and operational reliability.

8. Avoiding Additional Damage

• Risk of Disassembly: Removing large components like turbine casings can introduce new damage or alignment issues during reinstallation.
• Advantage: In-place machining preserves the existing setup, reducing the risk of additional wear or damage.

Key Steps in In-Place Re-machining

1. Inspection:
   • Assess the flange for wear, corrosion, and damage.
   • Measure deviations from flatness and alignment.
2. Setup:
   • Mount portable machining equipment directly onto the flange.
   • Align the tools with the turbine shaft and other reference points.
3. Machining:
   • Mill or grind the flange to restore flatness and proper dimensions.
4. Verification:
   • Use precision measurement tools to confirm alignment and surface tolerances.

In-place flange facing of Francis hydroelectric turbine flanges is critical for maintaining alignment, efficiency, and reliability. It minimizes downtime, reduces costs, and ensures the turbine continues to operate at peak performance while avoiding additional risks associated with disassembly and reassembly.  Congratulations to MBK EIRL for capturing this application so well!

Contact us today to learn how CLIMAX solutions can enhance your equipment’s performance and minimize downtime!