New TRI Spring-bed for  a GE Thrust Bearing

Shown here is an entirely new “Spring-bed”   manufactured by TRI for a Thrust Bearing that is used in a GE vertical hydro turbine-generator.   This TRI spring-bed is made using springs that are designed so that the thrust bearing is “floating” between the upper and lower limits of vertical spring travel when at rest and when  under maximum hydraulic force downward.  The springs are  selected from a production run for a uniform spring rate.     Careful attention to detail is required during final assembly to assure a uniform  spring-rate over the entire spring bed.

 

 

 

 

 

Double Insulated Saddle Block

A TRI “double insulated” saddle block is an assembly that has two layers of insulation sandwiched in the assembly of the steel parts of a saddle block on a steel bearing.  In the assembly shown here, the middle layer of steel has a threaded hole for a ground detection wire to be connected.  The insulating material is NEMA Grade G-10, an epoxy-fiberglass product. The resistance across each insulation layer is in excess of 550 megohms .

 

 

 

 

 

 

Machining and Tooling Package to  Maintain  TRI Align-A-Pad  Bearing

TRI manufactures and supplies packages of specialized machining and tooling equipment that duplicates the corresponding equipment that is used at TRI to  finish machining the Babbitt bores of the bearing pads and  to set the assembled clearances in the completed bearing pad and housing assemblies.  TRI prefers to provide closed secure crates in which to store and to ship the various tooling parts, but crates are optional.

 

 

 

 

 

 

TRI Synchronous Condenser Conversion Package

TRI provides overall system design for synchronous condensers based on TRI Patents 5,610,500 and 5,886,505. Shown here is a synchronous condenser that was converted from a 115 MVA GE Turbine-Generator.  TRI designed. manufactured and supplied the components including the extension shaft, journal and thrust bearing package, a step-up gear  and disconnect coupling, plus a new oil system.  New DCS controls were used.  The drive motor and fluid drive came from a dismantled plant. The unit is easy to start and synchronize. It is very reliable, typically running over 400 days without maintenance.

 

 

 

 

TRI System Design and Components for Mating a new  Generator to an Existing Steam Turbine in a New Plant

TRI provided engineering guidance on construction of a new power plant, generally consisting of optimum method for locating the generator relative to the turbine and for mounting the generator. In this case, a new surplus GE LM6000 Generator was driven by an existing Steam Turbine, about 60 MW capacity. TRI’s responsibilities included designing and       manufacturing the shaft coupling components, the soleplates and keys for the generator, as well as  performing the torsional critical speed calculations.

 

 

 

 

 

 

TRI Bearing System, Extension Shafts, and Flexible Coupling to  Connect a new Aero-derivative Engine to an Existing Generator

TRI was responsible for designing, manufacturing, and supplying most of the components of the power train, shown here, connecting a  30 MW gas turbine to  an existing generator. Included are the pedestal design, bearing housing, extension shafts, flexible coupling elements, and the journal and thrust bearing with limited end float for earthquake protection.

 

Emergency Lube Oil Pumping System

The principal components of an emergency lube oil system newly designed by TRI are shown: A Positive Displacement Pump coupled to an AC Motor, a Filter, Pressure Gages, an Uninterruptible Power Supply (UPS) with a full complement of batteries, and a Variable Frequency Drive (VFD).    

Upon a start signal from either a low pressure switch, a relay monitoring loss of AC Power for the main lube oil pumps, or a manual switch, the VFD starts and brings the AC motor and attached lube oil pump to speed in less than 0.7 seconds, faster than is done by most 3-step DC motor starters.  

All of the components are commercially available, but must be carefully matched together to meet certain design criteria and electrical codes.  The essence of the design is the use of AC instead of DC Technology. The reason for AC design:  It is difficult to find anyone who understands DC motors and DC starters. 

 

 

TRI’s Large Centrifugal  Babbitt Casting Machine

TRI designed and built this large centrifugal Babbitt Casting Machine in 2009, and has used it very successfully for newly Babbitted and for rebabbitted Journal Bearings. Bearings with outside diameters as large as 70 inches, lengths up to approximately 40 inches, and weight up to 20,000 lbs are Babbitted here