The turbine rotor is the heart of the machine, a precision-forged and machined component rotating at 3,000 or 3,600 RPM under extreme temperature and stress. Rotor-related spare parts must meet the highest standards of material quality, dimensional accuracy, and balance to ensure safe, reliable operation.
AQ Process Systems sources and exports journal sleeves, coupling assemblies, thrust collars, balance weights, and turning gear components for steam turbine rotors across all frame sizes. We support both mono-block and built-up rotor designs from all major manufacturers.
All rotor components are supplied with full material certification (per EN 10204 3.1), dimensional inspection reports, and hardness certificates. Critical items like couplings and thrust collars include NDE (UT, MT, PT) documentation.
| Component | Specification | Description |
|---|---|---|
| Journal & Bearing Areas | ||
| Journal Sleeves | Cr-Mo-V or SS | Ground and polished | Chrome-plated option | Replaceable journal sleeves protecting the rotor shaft at bearing locations, ground to mirror finish. |
| Thrust Collars | Forged alloy steel | Precision-machined faces | Thrust runner surfaces transmitting axial thrust loads to the thrust bearing assembly. |
| Shaft Seals (Rotor Side) | Labyrinth seal strips | Brass, SS, or nickel alloy | Rotor-mounted labyrinth seal components, seal strips, seal holders, and spacer rings. |
| Couplings | ||
| Rigid Couplings | Forged alloy steel | Bolted flange type | Turbine-generator and turbine-turbine rigid coupling halves, machined with bolt holes, centering spigot, and coupling bolts. |
| Flexible Couplings | Diaphragm or gear type | Accommodating misalignment | Flexible coupling assemblies for applications requiring angular and axial misalignment tolerance. |
| Coupling Bolts & Nuts | High-tensile alloy steel | Fitted or body-bound | Precision coupling bolts, fitted bolts maintain coupling concentricity, body-bound bolts transmit torque through shear. |
| Balance & Dynamics | ||
| Balance Weights | SS or alloy steel | Screw-in, clip, or weld-on | Rotor balance correction weights, installed at designated balance planes during shop or field balancing. |
| Vibration Probes | Eddy current proximity | 8mm or 5mm tip | Shaft vibration monitoring probes measuring radial displacement at journal bearing locations. |
| Keyphasors | Eddy current | Once-per-revolution reference | Speed and phase reference sensors providing the once-per-revolution signal for vibration analysis and overspeed protection. |
| Turning Gear | ||
| Turning Gear Motors | Electric motor | Low-speed geared | Drive motors for the turbine turning gear, rotating the rotor at low speed during startup, shutdown, and standby. |
| Turning Gear Pinions | Alloy steel | Hardened teeth | Engagement pinion gears meshing with the rotor turning gear ring, including engagement mechanism. |
| Turning Gear Bearings | Rolling element | Motor and pinion shaft bearings | Replacement bearings for the turning gear motor shaft and pinion shaft assemblies. |
Parts are manufactured to OEM specifications with full material certification, dimensional inspection, and NDE documentation as required. Provide the turbine manufacturer, frame/model designation, and part number for precise identification.
The most common rotor-related spares during major overhauls are journal sleeves (wear and scoring from bearing contact), coupling bolts (fatigue and fretting), thrust collars (wear on thrust faces), balance weights (correction after blade replacement), labyrinth seal strips (rub damage), and turning gear pinions (tooth wear).
Journal sleeves are specified by the journal diameter (bore), overall length, wall thickness, material grade, surface finish requirement (typically Ra 0.2-0.4 µm), and any chrome plating specification. The interference fit between the sleeve and rotor shaft is critical, we machine sleeves to the exact OEM tolerance.
Yes. We supply fitted (body-bound) coupling bolts manufactured to the exact diameter, length, and material specification of the original. Coupling bolts are a critical safety item, they must be manufactured from the correct grade of high-tensile alloy steel with full material certification and NDE (UT and MT) documentation.
The turning gear slowly rotates the turbine rotor (typically 3-5 RPM) during startup warm-up, shutdown cool-down, and extended standby periods. This prevents thermal bowing of the rotor, if a hot rotor stops rotating, the top becomes hotter than the bottom, causing a bow that creates severe vibration when restarted.
Yes. We supply eddy current proximity probes for shaft radial vibration, axial displacement, and speed measurement, compatible with Bently Nevada (GE), Emerson (CSI), SKF, and other monitoring system platforms. We also supply extension cables, proximitors (driver modules), and keyphasor sensors.
Share your turbine make, model, and part numbers, we respond within 24 hours.