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Wynoochee Hydro Mechanical Repairs Fall 2014 to Spring 2015
During a recent attempt to eliminate a tenacious oil leak on the turbine generator at Wynoochee, a number of problems were discovered and repaired. These included failed welds inside the generator support structure, a failed rubber turbine guide bearing, a damaged turbine shaft seal, silt plugs inside the heat exchangers and drain lines, and a worn generator shaft support that allowed the shaft to swing like a pendulum. The 15 megawatt Wynoochee Electosila Generator and LMZ turbine, which were purchased shortly after the fall of the Soviet Union, were installed in 1994.
Figure 1: Flying out the damaged generator bracket on Christmas Eve.
FIGURE 2. The 35,000 pound bracket sits on the 20-foot diameter turntable at A.F. Dick Manufacturing Machine Shop in Astoria, OR (Contact Art Dick at 503-458-6292). Art Dick was awesome and allowed our bracket to be slipped in the schedule between an order for rocket bodies for NASA and a giant hydro generator shaft from CA.
Figure 3. A chilling effect: The bronze interference ring is cooled with dry ice to shrink fit for installation.
Figure 4. Carrying the sub chilled interference ring to the thrust block for insertion. Art Dick is in the center.
Figure 5. Inserting the sub chilled bronze rings into the thrust block.
Figure 6. Machining the vertical keyway through the surface of the new bronze interference rings with a large shaper. The interference fit of the bronze ring in the steel thrust block is 0.009 inches. The bore of the block was subsequently machined on the Betz Boring Mill to a o.oo3 interference fit between the bronze bore and the steel generator shaft.
Figure 7.Flying in the restored bracket. Note the sun has not come up.
Figure 8. Insitu machining of the new, welded on, large generator shim. We replaced the 8 stacks of layered shims we found beneath the feet with on large shim.
Figure 9. Finished mounting pad (large shim welded on).
Figure 10. In the hot seat, the generator thrust block is heated to allow it to slip overthe generator shaft.
Figure 11. Lowering the heated thrust block onto the generator shaft.