Why Align?

• Correct bearing loading, reducing vibration & chance of bearing failure
• Correct misalignment caused by turbine foundation settlement
• Minimize rotor stresses due to improper bearing positions
• Prevent new seals from rubbing
  • Consideration for Component distortion
  • Correct Internal misalignments
  • Ensure proper reassembly

  MD&A provides turbine owners with the greatest depth of Topless Alignment® experience in the power generation industry. Our alignment process is a proven technology accompanied by an outstanding record of successful applications on nearly all makes and models of machines.

  The Topless Alignment® Service, or Diaphragm Alignment, starts with the centerline measurements, which were made with “Tops-Off” only. Then the shell horizontal joint distortion is measured & is used to determine centerline component Tops-On to Tops-Off movements. The calculated movements are used as offsets when aligning in the “Tops-Off” condition. This saves any power utility man-hos and reduced outage duration.

  MD&A engineers have successfully aligned over 1700 steam turbine sections using the Topless Alignment® method. Our projects have a remarkable record for “lack of rubbing.” We believe this historical track record of success is an important fact that differentiates our service from those available elsewhere in the industry.

  

  MD&A Alignment Engineers bring both depth and breadth of experience to the turbine deck. Each of our Alignment Engineers performs between 10 and 25 turbine section alignments per year. This depth of experience allows our engineers to constantly sharpen their skill sets and apply some of the most modern techniques available. Our experience base includes successful projects dating back more than 30 years.

  Our Alignment Engineers have the expert knowledge needed in order to interpret the data. They make sure they have valid data for your machine. Each engineer’s broad base of experiences contributes to the overall value we provide as your alignment contractor. You can expect dependable and accurate results every time you hire MD&A to align your turbine.

  Charles Monestere, MD&A’s Laser Alignment Services Manager, said:

  “Our alignment engineers are top in their field. They have been working many years, some decades, on different turbine-generator alignment projects honing their skills. Our alignment team is dedicated and responsive to the customer’s specific alignment needs and does their best to deliver the quality expected and the service when needed. A number of service providers send technicians who just collect data for the customer. Our engineers do the alignment calculations and review options with the customer. Select your alignment engineer / specialist carefully. Not all are created equal!”

  Have MD&A perform a Topless Laser Alignment® today, call Charles Monestere at (518) 399-3616 or use our Contact form.

  

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The unit was forced from service due to turbine bearing failures. In a quick turnaround, journal refurbishment occurred in the field and was completed by MD&A Machining Services, while bearing repair occurred at MD&A Bearings Seals & Hydraulics Division in Euclid, Ohio, USA.

During the outage, bearings 1-8 along with the thrust bearing was removed and visually inspected to determine suitability for continued use. Bearings 3-6, all elliptical-type journal bearings, were found damaged and sent to MD&A (Ohio, USA) for repair. The bearings were refurbished using MD&A’s proven methods and final bore machining was completed after as machined journal dimensions were determined.

In addition to bearing repair, 8 journals were also restored. Journals 3-6 required machining and honing to remove minor radial grooving utilizing a stationary journal machine. Journals 1, 2, 7, and 8 only required polishing, which was also completed using stationary journal equipment. Because only polishing occurred, these journals had minimal stock removed and the customer continued to use the current size bearings as bearing clearances were well within specification. All journals met or exceeded the customer’s acceptance criteria.

Our team worked “in sync” with Petro Vietnam to fulfill all compliance requirements both in the USA and Vietnam to avoid any delay in transit and customs clearance. With all divisions working together, this team approach ensured the job was completed quickly and efficiently, minimizing the forced outage duration.

All incoming inspection data was provided to the customer daily along with an updated report. Inspection data consisted of axial journal measurements and concentricity checks. The same data was taken during the final inspection along with the addition of surface finish measurements.

Technical directors from MD&A provided oversight throughout reassembly and startup. During bearing reassembly, contact checks and clearance checks were performed.

Additional work completed during reassembly included:

• Coupling disassembly and alignment checks
• Alignment corrections by adjusting locations at bearings 1-6
• Alignment corrections by moving the generator assembly horizontally
• Disassembly of the thrust bearing to facilitate coupling disassembly
• Adjusting the position of the HP/IP turbine shell to match bearing moves at bearings 1 & 2
• Visual inspection and repairs of the thrust bearing pads and runner
• Final alignment checks and reassembly
• Oil flush utilizing on-base pumps

Our team quickly restored Petro Vietnam’s 8 journals and repaired 4 elliptical journal bearings, providing exceptional quality of workmanship and superior communication that met their expectations and exceeded the schedule.

MD&A experts are there when you need us! Providing comprehensive inspection and repair of turbine-generator components for many different OEMs across the world.

Our specialized services range from gas or steam turbine-generator inspections and repairs to parts and controls. Call MD&A today at +1 (518) 399-3616 or use our Contact form.

References available on request

The post Petro Vietnam’s Rapid Bearing Repair and Journal Machining appeared first on MDA Turbines.

In-place stationary shaft machining allows MD&A to repair damaged journals, collector rings, and seal areas without removing turbine and generator rotors from the unit. The compact setup easily fits under LP hood radii to allow for machining along the complete rotor train.

Saving you time and money, this capability eliminates unnecessary downtime. Advantages include:

Cost Effective:

• Reduction in crew size, as disassembly is limited to removal of outer bearing cover and Babbitt bearing.
• Shorter schedule duration.

Lay down area reduction:

• Portable lathes occupy valuable space on a turbine deck, whereas stationary journal equipment requires only three standard gang boxes.
• Repairs can be performed with the rotor left in the unit.

Time Constraints:

• Most stationary journal repairs can be completed in three to four shifts, start-to-finish.
• Reduces schedule impact by eliminating disassembly & reassembly of the steam turbine.

Our technicians have 20+ years of experience with in-place stationary shaft repairs.

MD&A experts first perform a complete Foreign Material Exclusion (FME) of the bearing standard to ensure metal shavings do not enter the lube oil system and the packing gland is sealed to prevent intrusion of foreign contaminants.

Diametrical measurement inspections and concentricity sweeps are then completed, and findings are discussed with the customer prior to machining.

Next, the honing and polishing process is performed – surface finishes up to 2Ra are achievable. The concentricity of the journal is checked throughout honing process to maintain centerline.

The machining process allows for a perfect blend of newly machined diameter to the existing radius.

We also offer Babbitt bearing restoration in our facility upon completion of shaft machining, to accommodate for the new diameter.

MD&A can currently accommodate shaft diameters from 9 – 24 inches with additional sizes supported when the schedule allows. This new service increases our ability to respond quickly to our customers’ ever-changing needs.

MD&A continues to invest in new capabilities that enable us to expand our quality service and repair offerings. 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.

For additional information, call MD&A’s Turbine-Generator Repair Facility today at (314) 880-3000 or use our Contact form.

The post In-Place Stationary Shaft Machining Capabilities appeared first on MDA Turbines.

First unit:  This was a major outage and generator test & inspection. In addition, this unit was retrofitted with a new rotor, bearings, and steam path components that required machining, including installing and fitting new nozzles. MD&A provided Project Management, Technical Direction, a Controls Engineer, and a Vibration Engineer for startup and balancing.

In order to maintain the outage’s schedule, MD&A worked closely with the OEM’s engineering team to ensure that the new retrofitted components were installed correctly and to resolve any technical or engineering issues quickly. MD&A’s knowledge, experience and our skilled project manager and technical adviser resulted in this successful outage.

MD&A’s Repairs Division personnel performed onsite final machining of the nozzle plates and their associated shell locations. Our repair technicians also performed on-site diaphragm repairs.

MD&A also provided a packing installation specialist to install and final machine new upgraded packing.

To support the major outage schedule and expedite the on-site work, MD&A sourced equipment locally to overcome the time required to get the specialty tooling and equipment trailers through Colombian customs.

This unit was started up without incident and has been operational since.

Another unit: MD&A provided Project Management and Technical Direction on a Steam Turbine Generator (STG) major inspection and performed Generator testing and inspection. MD&A also provided a balance engineer, Topless Alignment®, and start-up commissioning support through our Turbine and Generator Controls Division.

The steam turbine had not been inspected for 23 years. Using MD&A’s pre-outage planning processes and experience, the execution team immediately started working to identify & mitigate potential project risks. One example was special tooling, which needed to be located and prepared for use.

After the balancing work was performed, the machine was started up smoothly, synchronized, and brought to full load. This unit has been operational without issue since this start up, after 23 years without maintenance.

Another unit: MD&A worked this unit and the one above in parallel to minimize the impacts on schedule caused by the emergent work.  MD&A provided Project Management, Technical Direction, and balance support at start up for this valve, bearing, and turning gear inspection.  MD&A also supported conversion of the Mechanical Hydraulic Controls (MHC) to Electro-Hydraulic Controls (EHC) (with the exception of the mechanical overspeed trip, which was retained).

This unit was started up without incident and has been operational ever since.

Last unit:  This major outage was similar to the other unit’s scope including valve, bearings, and turning gear, but was expanded to include generator bearings and coupling alignment. As was the case for all units, a lube oil flush was performed. For this start up, vibration data was analyzed remotely by MD&A, saving the customer the mobilization cost for the vibration specialist.

This unit was also started up without incident and has been operational ever since.

Epilogue: These successful outages demonstrate the full-service capability, responsiveness, and flexibility that MD&A can provide. The customer was very appreciative of our flexibility and our ability to adjust our execution plan as required to support the overall outage plan.

Throughout the U.S. and around the globe, MD&A provides responsive support, thorough communication, and excellent execution, making MD&A the service provider of choice for numerous power generation asset owners who desire a one-stop solution for all of their turbine-generator needs.

Call MD&A today at +1 (518) 399-3616 or use our Contact form.

Also be sure to sign up for our MD&A Insight e-newsletter delivered quarterly.  Fill in sign up form on the left-hand side and hit SUBSCRIBE!

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