At Berg Engineering, we take pride in our commitment to excellence and our ability to tackle complex projects head-on. Recently, we had the privilege of partnering with Siemens for a critical shutdown project at the NRG Power Station in Gladstone. This undertaking was no small feat, as it involved the meticulous task of “Re-blading the IP Rotor” and machining “IP Rotor Bearing No 3.” In this blog post, we will delve into the details of these challenging yet rewarding tasks that we successfully completed within a tight two-week timeframe.
Re-blading the IP Rotor
The heart of the project revolved around the IP Rotor, a massive piece of equipment measuring Ø1000 x 4100mm and weighing a staggering 14 tonnes. Our first step was to receive this rotor and set it up on Berg’s purpose-commissioned lathe – a testament to our commitment to investing in cutting-edge machinery for precision work.
The process involved several critical steps:
Removing Old Blades: We meticulously machined the old first-stage blades to safely detach them from the rotor. This step required precision and attention to detail to ensure the rotor’s integrity remained intact.
Groove Profile Machining: To accommodate the installation of new blades, we expertly machined groove profiles. This critical step ensures that the new blades fit seamlessly, contributing to the rotor’s optimal performance.
Installing New Blades: The integration of new blades was a highly delicate operation. Ensuring a secure fit and alignment was crucial to the overall success of the project.
Machining Outside Diameters: We meticulously machined the outside diameters of the rotor, achieving the precise specifications necessary for its proper functioning.
Final Inspections and Loading: Before completion, the rotor underwent rigorous final inspections to guarantee its readiness for transport. Our team left no stone unturned in ensuring that every detail was perfect.
IP Rotor Bearing No 3
Simultaneously, we undertook the machining of IP Rotor Bearing No 3, further demonstrating our multitasking capabilities during this demanding shutdown.
The steps for this aspect of the project included:
Setup and Machining of Main Bore: Carefully setting up the bearing and machining the main bore was essential for the bearing’s functionality.
Oil Feeder Relief and Oil Jack Pocket: Precision machining was again employed to create oil feeder relief and oil jack pockets, crucial for the bearing’s lubrication and smooth operation.
Cleaning and Assembly: We meticulously cleaned and assembled the bearing halves, ensuring that they met the highest standards of quality and performance.
Final Inspections: Just as with the IP Rotor, the final inspections were an integral part of the process to guarantee the bearing’s reliability.
Our commitment to quality, precision, and efficiency shone through during this Siemens shutdown project at NRG Power Station Gladstone. We are proud to have completed these challenging tasks within the allocated two-week timeframe, demonstrating our ability to deliver results under tight schedules.
At Berg Engineering, we believe that challenges are opportunities to showcase our expertise, and this project was no exception. We look forward to taking on more complex tasks in the future and continuing to provide exceptional service to our valued clients. If you have any inquiries or require our services, please feel free to get in touch with us.
