MD&A provided all project management, inspection and analysis, supervision, labor and tooling for the owner’s dual-unit work scope.

During disassembly of the first unit, MD&A Gas Turbine Services personnel first removed roof sections, recorded thrust and lift checks, removed all relevant casings, and labeled/removed relevant piping/hoses. Half shell readings were taken on the turbine and compressor by recording all rotor and stator tip clearances.

The service run 7FA.04 hot gas path components were inspected and analyzed onsite by specialists from MD&A’s San Antonio Service Center to determine the potential for future component repairs. Our team has extensive knowledge on a range of gas turbine component repairs, including weld repair, blending, dimensional restoration, and machining. They can extend the service life of gas turbine components whose OEM service limit has passed or whose configuration is no longer suitable to operate. These experts provided feedback on the component repairability.

For these outages, the turbines’ first, second, and third stage buckets were removed and replaced with Customer provided components.

Additionally, nozzles and shrouds were removed and exchanged. For the compressor, stage 14 through EGV’s stator vanes were removed; new vanes were drilled and pinned upon installation.

MD&A inspected T1 and T2 bearings and determined replacements were required, in addition to new thrust bearings.

All combustion components were removed and inspected. Transition pieces, liners, flow sleeves, outer bellows, inner crossfire tubes and fuel nozzles were exchanged during reassembly.

The GE® 7FH2 generator was disassembled, including coolers, oil deflectors, gas shields and bearings. Hydrogen casings and seals were removed and sent to MD&A’s Bearings, Seals and Hydraulics Division in Euclid, Ohio for refurbishment.

The generator field was then removed and transported to our Turbine-Generator Repair Facility in St. Louis, MO for a complete field rewind utilizing the existing copper. The rewind process was expedited to allow for the rewound field to be installed in the sister unit. A spare generator field from the Customer’s inventory was installed on the first unit, to support the expedited outage schedule.

MD&A experts inspected the generator stator and found areas of greasing indicated a loose wedge structure and necessitating a full stator rewedge. Core and bellyband tightening was also required.

Stator electrical testing was completed, and electromagnetic core imperfection detections (ELCID) tests were conducted before and after wedge replacement.

MD&A’s Generator Experts replaced the wedges, then completed bellyband and core tightening. With the stator repairs complete, the generator field from owner/operator’s inventory was able to be installed.

During component reassembly, new hydrogen seals and springs provided by MD&A’s Bearings, Seals and Hydraulics facility were utilized.

Following reassembly of the gas turbines and generators, coupling alignments were performed by MD&A technical experts in full collaboration with the Owner/Operator.

MD&A’s Turbine and Generator Controls Division performed a complete inspection of the exciter and inverter equipment, ensuring no issues on return to service. Startup was completed with no operational concerns and full compliance with emissions standards.

Following execution of the first outage, MD&A personnel shifted focus to the sister unit, to complete a nearly identical work scope.

For this unit, turbine first, second, and third stage buckets were replaced as were nozzles and shrouds.

A spare Customer provided Gas Turbine rotor was installed after conducting green rotor inspections and repairs. At startup the green rotor run-in was completed in compliance with industry standards.

As with other unit, all Technical Information Letters were listed as completed, as were all Extra Work Authorizations.

For this unit, the service run generator field was removed for transport to our Turbine-Generator Repair Facility for a complete field rewind utilizing the existing copper. This field would be rewound and returned to Customer after the outage to be held as inventory.

Conclusion

Throughout these major overhauls on two 7F.04 Gas Turbines and 7FH2 Generators, detailed daily written and visual (photographic) job reports and updates documented all current and planned activities, alerts, needs, schedules, recommendations, and resolutions.

For every repair job, large or small, the speed and effectiveness of our response team is matched only by the depth and breadth of our engineering expertise.

Successful completion of these back-to-back projects clearly exemplifies the multi-divisional breadth, versatility, and corporate commitment of MD&A as a premier non-OEM service provider to the global gas and steam turbine-generator market. Call us at (518) 399-3616 today or use our contact form.

The post Back-to-Back Major Overhauls on Two 7F.04 Gas Turbines and 7FH2 Generators appeared first on MDA Turbines.

View our video to see the process and then call MD&A today at (518) 399-3616 or use our Contact form.

MD&A’s Gas Turbine Rotor Life Extension Program provides solutions for your aging fleet.

Our goal is to meet your operating strategy for remaining life through validation, repair, or replacement of life limiting components.

MD&A will evaluate your specific needs with input from you, including Operating History & Forecast to provide the best solution.

Our experts will assess your rotor with specialized inspections including Metallurgical Evaluation and perform a Complete Engineering Analysis with modeling.

Next, we will discuss our recommendations and your options, ranging from specific component repairs or replacement, A Rotor Exchange Program or Full Rotor Replacement.

Our Turbine-Generator Repair facility in St. Louis, MO is fully equipped, featuring a Rotor Stacking Elevator with support equipment, Overhead Cranes, Blast Cleaning Facilities, Advanced Rotor Welding, Reverse Engineering Lab and a State-Of-The-Art High Speed Balance Facility.

MD&A is a premier worldwide manufacturer of heavy-frame gas turbine rotor components from replacement turbine wheels & disks to spacers.

Our components are Based on a reverse engineered – never fired – OEM design. Our solutions provide more robust, superior re-engineered components.

MD&A provides power generators around the globe with a full-service, OEM-alternative for your gas turbine. Together, we power through experience!

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Unlike steam turbine alignment, gas turbine alignment is performed with the upper halves installed, also called “Tops-On” alignment, and moves must be made in a specific sequence, adding to the overall challenge.

MD&A Alignment Engineers have experience with a variety of OEM’s allowing them to service a large portion of the installed fleet.

The most common issue with three bearing gas turbine models, such as the GE® 7B, 7E, and 7EA, is with casing slippage in the turbine/exhaust frame casing joints. The casings serve an important function as they support the bearings, rotor, and hot gas path hardware. It’s necessary that casings stay in position to keep the unit’s performance and efficiency at an optimal level.

On affected turbines with this issue, the casing slips downwards in relation to the exhaust frame. This causes misalignment of the #2 and #3 bearings, as well as, causing a vertical step change in the stationary component positions near the joint.

Two bearing gas turbine models, such as GE’s® 7F turbines, can also become misaligned over time. This is due to conditions including gravity sag, casing slippage, and thermal creep. These conditions cause shifting for both the casings and the T2 bearing, requiring the unit and its components to be precisely realigned.

Occasionally, turbine compressor discharge casings need to be replaced on older machines. Originally, these casings were fabricated with welded joints, which have been shown to be susceptible to casing creep. As the metallurgy changes over time, the casings distort, leading to significant performance issues. This is resolved by completely replacing the compressor discharge casings.

The process for our specialized Gas Turbine Alignment starts with an internal inspection of the unit. Partial disassembly is required to identify the issues. The most common signs of misalignment are blade rubs. These are caused when the rotating blades come in contact with the casings after they have slipped or become distorted. This condition is visually evident on both the casings and the blades themselves. This type of damage can only be seen and assessed if the unit is taken apart. Rotor position to casing measurements is also taken and recorded. Once the cause of damage is understood, the repair phase begins.

The typical Gas Turbine Alignment consists of realigning the bearings and changing the dowel pins in the turbine/exhaust casing vertical joint. On the 7F series units, only the T2 bearing is alignable, since the T1 bearing is secured within a cylindrical fit. Alignment is a fairly complex undertaking due to very small clearances and tight tolerances. The process requires specific expertise, equipment, and experience to properly diagnose and resolve the casing alignment issues.

In decades past, on earlier models, misalignment was less of an issue. Older units were more forgiving and kept running even when misaligned. Today, it’s much more of a concern. Alignment affects clearances and clearances affect output and air quality, which is now heavily regulated.  With today’s modern units and high-efficiency levels, even small rubs of rotating blades with the casings open clearances and degrades the efficiency and output of the unit.

Our Alignment Engineers have the knowledge needed in order to interpret the data. Each engineer’s broad base of experiences contributes to the overall value MD&A provides to our customers. You can expect dependable and accurate results every time you hire MD&A to align your turbine.

MD&A’s specialized services range from Compressor & Turbine Rotor Repairs to Plant Performance Testing and Analysis. We provide immediate access to expert help when you need it, where you need it. For every repair job, large or small, the speed and effectiveness of our response team is matched only by the depth and breadth of our engineering expertise.

Call our Gas Turbine Services at (518) 399-3616 or use our Contact form.

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Power plant owners and operators have entrusted their turnkey turbine-generator overhauls to MD&A for close to four decades.

Our team of seasoned professionals has a broad range of experiences whose skill sets cover both common and unique makes and models of turbo machinery from around the world.

Our reputation for providing objective advice, effective project management, and high-quality repairs has enabled MD&A to become one of the most recognized and trusted names in the power generation industry.

We are your full-service, OEM-alternative gas turbine service provider!

View our new Gas Turbine Services’ capabilities video below and then call Gas Turbines Services today at (518) 399-3616 or use our Contact form.

Mechanical Dynamics & Analysis provides power generators around the globe with a full-service, OEM-alternative for your gas turbine. We provide the expertise necessary to address both planned and forced outages of many types of gas turbines.

Our routine maintenance capabilities range from a full Major Inspection to a Combustion or Hot Gas Path Inspection. We perform specialized services, such as performance testing and analysis, aligning gas turbine internal components, replacement, and alignment of compressor discharge casings and turbine shells.

MD&A’s Gas Turbine Rotor Repair Division in St. Louis, Missouri has the expertise for superior repair solutions. Our fully equipped one-stop shop has validated tooling for unstack, restack, inspection, balance, and repair for gas turbine rotors. MD&A has developed complete engineering models and inspection procedures to support various plant strategies for Rotor Life Assessment and Life Extension.

MD&A’s San Antonio Service center is an industry leader in gas turbine component repair. Our team has extensive knowledge on gas turbine hot gas path and combustion components. MD&A’s advanced coating system, on components, can provide oxidation and corrosion protection, and aid in temperature reduction.

We test and repair gas turbine fuel nozzles. MD&A supports multiple frame’s Standard Combustion, Multi-Nozzle Quiet Combustor & Dry Low NOx System 1.0, 2.0, and 2.6 systems.

Our experts offer refurbishment of gas turbine bearings. We stock replacement bearings to satisfy short-cycle turnaround requirements.

MD&A Generator specialists perform turnkey stator and field rewinds, and repairs of any type or OEM. We conduct full-scope electrical testing, visual inspections, and specialty tests, per customer requirements.

On staff, we have experts who specialize in Engineering Parts & Retrofits for Control and Excitation Systems. Our HMI simplifies power plant control and monitoring.

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We understand the importance of planning for major gas turbine overhauls, and our team can help coordinate and prepare for these planned outages. However, we also understand that forced outages can happen, and when they do, quick and efficient engineering responses are essential. Our experts are always available to provide fast and effective solutions for any issue that may arise.

Our gas turbine services experts are dedicated to helping power generation plants prepare for both planned and unplanned outages. Our project managers and technical directors are available 24/7 to provide the necessary technical and engineering support. Our team has the knowledge and expertise to address all types of turbine and generator issues, ensuring that your power generation plant runs smoothly and efficiently.

Why choose MD&A?

For over 40 years, our commitment to excellence has earned customer trust for all turbine-generator needs. We focus on delivering consistent quality and value with fast response, superior communications, and innovative solutions.

MD&A is easy to work with. We provide immediate access to expert help when you need it, where you need it. Around the corner or the globe, we ensure prompt, thorough communication and follow-through. For every repair job, large or small, the speed and effectiveness of our response team is matched only by the depth and breadth of our engineering expertise.

Find out today why so many power generators use MD&A to maximize operational effectiveness.

The Overhaul Gas Turbine Services capabilities that we offer include the following:

1.     Technical Direction

We have experienced technical directors and project managers who provide expert assistance in challenging cases of turbine-generator engineering.  These experts can handle complex technical issues in many different types of OEM equipment.

2.     Outage Planning

Through MAPS or Maintenance Advanced Planning Services, our experts evaluate and organize outage activities, to reduce or minimize outage times, getting you back online fast.

3.     Turnkey Inspections

MD&A offers a skilled support team for turnkey installation, maintenance, and gas turbine overhaul services to our clients. Our capabilities range from Combustion inspections to HGP and Major inspections.

4.     Rotor Life Assessment

A rotor life assessment can help decide if component Repair, Replace or Use is the best option for your gas turbine rotor to meet operational and maintenance forecasts.

5.     Gas Turbine Alignment

Our laser alignment services provide a reliable method of measuring and aligning gas turbine components, including alignment of compressor discharge casings and exhaust frames during replacement.

6.     Coupling Laser Alignment

MD&A experts can perform a shaft/coupling alignment with Pruftechnik laser technology. Our experts are skilled at utilizing this technology and use this equipment to perform reliable alignment services for our clients.

7.     Operational Alignment Diagnostics- CMM System

As part of our Gas Turbine Services capabilities the CMM (Coordinate Measurement Machine) system measures and monitors large equipment components and their movements precisely.

8.     Balancing & Vibration Analysis

Our team of experts uses influence coefficient balance methods to ensure a high-performance level of heavy rotating equipment. We also have our High-Speed balance facility located in St. Louis MO.

9.     Field Machining

For use on-site, our team supplies a range of portable steampath repair and field machining equipment. Our experts have many capabilities available in-shop.

10.    Control and Excitation Field Engineering, Consulting & Training

For gas turbine controls, generator excitation, and auxiliary systems, we have a staff full of OEM-skilled field engineers that handle multiple tasks like technical support, installation, training, consultation, and advanced troubleshooting.

11.     Turbine Foundation Monitoring

MD&A experts use multiple optical and laser measurements altogether in our advanced foundation measurement process to calculate the custom monuments in the turbine foundation.

12.    Turbine System Enhancements

Our experts can handle multiple phases of generator, gas, and steam turbine controls. We often provide targeted improvement in particular available system components to evaluate and enhance overall system performance.

13    Thermographic Survey

Our engineers utilize acoustic techniques and infrared thermography to pinpoint leakages and quantify them as per the industry-accepted standards.

14.    Thermodynamic Analysis

MD&A offers thermodynamic analysis to understand and improve cycle performance.

15.    Center-line Installations

Our team of technical support personnel, craft labor, and project managers have experience in providing affordable center-line installations of the diverse OEM-generated steam turbine-generator sets.

16.    Performance Testing & Analysis

Our Experts look at the overall testing objective of the power plant and provide suitable performance testing and analysis solutions.

Conclusion

In conclusion, our goal at MD&A is to deliver exceptional gas turbine services for our clients, addressing all aspects of gas turbine maintenance and repair including overhauls and more. We strive to ensure that power generation plants operate at optimal performance and efficiency with our expert support and technical expertise. To talk to one of our experts and find out all the services we offer, get in touch with us as soon as possible.

Check out our video: Gas Turbine Services Video

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