It has operated in Port Melbourne since it was founded and employs a workforce of around 30 depending on current projects. The resulting finished technical marvel is worth hundreds of thousands of dollars.ĪSSDA member Steel Castings Pty Ltd has its roots in the 19th century. The 'plumbing', the additional pieces which enable pouring the casting, is removed and the Pelton is heat treated at 1020✬ over a 23 hour cycle to strengthen the structure of the metal before final tempering and machining.įrom drawing to installation the procedure takes about five months. The casting has to cool for seven days before it can be inspected. The mould is constructed so that the metal flows into all areas of the shape in less than 30 seconds of pouring time. The stainless steel used is CA6NM, a modified grade 410, poured at a temperature of nearly 1600✬. Once the pattern is complete, the mould and cores are produced from sand combined with a bonding agent – 17 tonnes of sand were required for this mould. With only a 3mm tolerance window, this is something that can't be done by a computer, says Mr West. One of the skills involved in pattern manufacture is estimating the contraction allowances for the shrinkage and distortions that occur during cooling and heat treatment. The pattern took about five weeks to make followed by a week of refinements. For example, there are 64 measurements for each of the Pelton Runner's 21 buckets. Thousands of measurements must be checked. Technical Director Jim West explains the steps involved in achieving such a feat of engineering.įirst a wooden pattern is made from drawings. They are designed to withstand water cascading onto them from 400m above for 20 to 30 years to generate about five megawatts of electricity.ĭespite their complex shape, the Peltons were cast in a single pour. Measuring 2m in diameter and weighing in at 3.5 tonnes, these units are the largest so far. Steel Castings have been making Peltons since the mid-90s. Steel Castings Pty Ltd, situated in Port Melbourne, has a reputation for precision moulding which has secured the firm contracts to produce two 'Pelton Runners' – the heart of the turbine – for a Victorian Hydro Power Station, working with the Norwegian designers, GE Australia and Acron Engineering. At a time when so many industrial processes are computer-driven, there is still a place for human knowledge and experience in the highly specialised area of hydro-turbine manufacturing.
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