As a result, over 40 years later, MD&A has evolved from a small firm to a large service provider with over 600 employees reaching more than 100 customers each week during outage season.  The reputation for outstanding service in the US has enabled MD&A to spread globally with parts, repairs, and services on large turbine-generator sets.

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Here are the significant initiatives we have in place to ensure continuous growth and development within our organization.

Mentoring Program and Succession Planning

Kristin Esterby, our Human Resources Director, addressed the critical need for effective succession planning, particularly as many of our seasoned professionals approach retirement. «We’re facing a unique challenge with our workforce,» Kristin noted. «Not only are we navigating the aftermath of the COVID-19 pandemic, but we also have an aging workforce.» This demographic shift necessitates proactive measures to maintain our high standards of service and expertise.

To address these challenges, MD&A has implemented several strategic initiatives:

• Succession and Talent Planning: Our approach focuses on evaluating individual performance, setting clear goals, and creating tailored development plans. This ensures that our employees are prepared to step into critical roles as they become available.
• Mentoring Programs: We are in the process of developing both formal and informal mentoring programs. These initiatives aim to facilitate knowledge transfer between experienced leaders and newer employees, fostering an environment of continuous learning and growth. Technical-specific mentorships are also being established to address the unique challenges of our industry.

Kristin emphasized the importance of these programs in bridging the knowledge gap and ensuring a smooth transition of expertise. «Mentorship is not just about transferring knowledge; it’s about building relationships and creating a culture of support and mutual growth,» she explained.

Learning and Training (LEAP)

One of our most impactful initiatives is the Leading Effectively at Power (LEAP) program. This week-long training event brings together 20-25 leaders from various divisions to enhance their leadership skills. The curriculum covers crucial topics such as finance, legal considerations, and change management. Participants engage in interactive sessions that promote cross-functional learning and collaboration.

Kristin highlighted the dual benefits of the LEAP program: «Participants not only gain insights from our expert instructors but also learn from each other, which is invaluable for their development as leaders.» This collaborative learning environment helps build a cohesive leadership team equipped to handle the complexities of our industry.

In addition to LEAP, we are launching a pilot series called Leadership and HR 101. This program aims to equip our leaders with foundational knowledge in key areas such as human resources and basic management principles. By providing this training, we ensure that our leaders are well-prepared to manage their teams effectively and foster a positive workplace culture.

Engineers in Training (EIT) Program

Charles Monestere, our General Manager of Technical Services, provided insights into the Engineers in Training (EIT) program. Initially, MD&A focused on hiring experienced engineers. However, in 2009, we shifted our strategy to recruit recent graduates, recognizing the value of fresh perspectives and new talent. This structured program combines intensive classroom training with hands-on, on-the-job experience under the mentorship of our seasoned engineers.

Charles outlined the program’s objectives: «We aim to hire about ten new engineers each year. Our goal is to provide them with a comprehensive understanding of our operations and prepare them for long-term careers with MD&A.» The EIT program has grown significantly since its inception, reflecting its success in developing well-rounded engineers who are ready to contribute to our mission.

Personal Experience: Colin Baker

To provide a personal perspective on the EIT program, Colin Baker, a Field Engineer and recent EIT program graduate, shared his journey. «I joined MD&A straight out of college with minimal turbine experience,» Colin recounted. «The EIT program allowed me to learn from experienced engineers and apply that knowledge in the field.» He emphasized the importance of networking and continuous learning, which are integral components of the program.

Colin’s story is a testament to the program’s effectiveness. He highlighted how the EIT program not only provided technical training but also fostered a supportive environment where he could grow both professionally and personally. «The mentorship and hands-on experience I received were invaluable. It helped me build confidence and develop the skills necessary to excel in my role.»

Looking Ahead

At MD&A, we believe that investing in our people is crucial to our long-term success. Through our comprehensive mentoring and training programs, we are preparing our workforce to meet future challenges head-on while fostering a culture of continuous learning and development. These initiatives ensure that we remain at the forefront of the power industry, delivering excellence and innovation.

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Before the retrofit, the power generation customer was experiencing voltage regulation issues. They understood the importance of determining the source of these problems and remediating them as quickly as possible. Failure to do so promptly could result in significant and costly damage caused by overheating of generators and motors. These issues can also lead to transmission losses or voltage collapse.

The customer attempted to resolve these problems on their own before asking MD&A for assistance. Unfortunately, they were no longer able to service and maintain the original voltage regulator due to its age. Ultimately, MD&A’s expert technicians were brought in to replace it. They selected and installed a digital excitation control system to ensure precise and consistent voltage moving forward. The voltage regulator interfaced with the plant’s distributed control system (DCS), the plant’s auto synchronization (25A) relay, and the existing generator lockout (86) relays.

To help ensure reliability and stability, the interface with the plant’s existing controls and protection equipment was also updated. To further help ensure safety and protection, the technicians also updated the generator protective relay interface, to make sure circuit breakers would trip if a fault is detected.

Once the new components were installed, MD&A’s experts conducted a thorough checkout and commissioning process. Offline commissioning began with the turbine not running. Prior to panel power up, wiring, power feeds, field switches, and instruments were carefully checked. Offline commissioning then continued with the turbine running at synchronous speed. This phase began with initial excitation startup and FCR gain tuning. It continued with saturation curve measurement, AVR gain tuning, offline OEL testing and setup of the exciter diode monitor.

Next MD&A’s technicians conducted synchronization commissioning. This started with an offline OEL and V/Hz review, by recording the settings and confirming they are correct for proper synchronization. Following, automatic synchronization was performed. Typically, the team will normally conduct manual synchronization first, but this was not possible due to some wiring issues that were discovered.

The team then commenced online commissioning with the unit running at 10% load. This phase consisted of AVR step tests, OEL gain tuning, UEL gain tuning, and power factor tuning. VAR control mode was conducted next.

The generator was brought up to full load and unity power factor. MD&A’s experts conducted AVR step tests and tuning. The unit was tested in all other control modes (manual, PF, and VAR) to confirm stable AVR operations.

The final commissioning phase consisted of setting up the data log, restart, and cleanup. Once completed, the unit was left to remain offline. The team provided the customer with a photographic documentation of the installation, a complete set of redline drawings, and the DECS-250N software configuration file. Further, they prepared a marked-up startup procedure checklist, to help ensure safe and successful future startups.

A report on further recommendations for system reliability was also produced by the MD&A team. It addressed two issues, one referring to a stop command, and the V/Hz limiter coming in frequently. Recommendations were made by the team on how to resolve each. Some instability issues were also experienced, and one of MD&A’s technicians worked with the plant’s I&C technician to adjust VAR PID settings to remedy the issue. As for the wiring issues that prevented manual unit synchronization, mentioned earlier, the team suggested that the customer correct the wiring on the voltage raise/lower switches to all for manual synchronization in the future. They also recommended that the customer test the field ground detection system at the next outage opportunity.

This project underscores MD&A’s ability to partner with in-house power plant service teams in a consulting capacity to resolve equipment issues before they grow into much bigger problems. MD&A’s Turbine and Generator Controls Division provided a turnkey solution, from equipment selection and installation, through testing and commissioning. Success stories such as this exemplify the professionalism and expertise that MD&A provides, and is the reason why MD&A is the go-to service company for power generation operators worldwide.

For any turbine or generator controls issue and to discuss creative resourceful solutions, call MD&A today at +1 (970) 224-2223 or use our contact form.

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An exhaust temperature spread refers to a high differential in readings between the thermocouples placed radially around the exhaust of a gas turbine. The worst exhaust temperature spreads occur when the hottest- and coldest exhaust thermocouple readings are grouped very closely (adjacent). Most exhaust temperature spreads are the result of combustion section problems that can lead (very quickly in some cases) to premature turbine blade (“bucket”) failures. In other words, exhaust temperature spreads are indicative of combustion troubles that can lead to catastrophic failure.

Most heavy duty gas turbines employ multiple combustors, called ‘can annular combustors,’ each of which produce high temperature gases that are “funneled” to the first stage nozzles of the turbine section where they are expanded to produce torque. Ideally, each one of these combustors should be receiving equal amounts of fuel and air which should result in relatively uniform hot combustion gas temperatures from each of the combustors entering the first stage turbine nozzles.

The turbine buckets rotate past each combustor at very high rates—from 50 times per second for a 3000 RPM machine, to as many as 85 times per second for a 5100 RPM machine.

It surprises most people to learn that there are no temperature sensors monitoring the hot combustion gas temperatures as they leave the combustors and enter the first stage turbine nozzles. There are many reasons for this, but the four most important ones are:

1. the currently available sensors are very expensive;
2. the currently available sensors are prone to fail quickly requiring frequent replacement;
3. a failed sensor could result in pieces entering the turbine section and causing catastrophic damage;
4. there is too much stratification of the gases flowing into first stage turbine nozzle making it impossible for one sensor to adequately sense the temperatures under all conditions.

So, how are these combustion problems detected by the exhaust thermocouples? It also surprises most people to learn that as hot combustion gases flow through the turbine stages there is very little mixing. Hot combustion gases from a combustor don’t travel axially straight through the turbine section (a phenomenon known as “swirl”), but they mix very little with the gases from adjacent combustors before they enter the gas turbine exhaust. It’s this fact (that very little mixing occurs as the hot gases pass through the turbine section) that allows the exhaust temperature thermocouples to be used to sense cold or hot spots in the gas turbine exhaust which are indicative of unequal fuel- and or air flows into individual combustors.

So, what causes most exhaust temperature spreads? Far and away, most exhaust temperature spreads are the result of mechanical issues. Plugged fuel nozzle orifices, enlarged fuel nozzle orifices and fuel nozzle assembly problems (loose components; worn components) are the most common causes of unequal fuel flow-rates. MD&A has In-Situ Air Flow Test stand capabilities that allow for immediate and conclusive data on gas turbine nozzle performance.

On liquid fuel-fired machines, liquid fuel flow divider issues can cause unequal fuel flow-rates, as can leaking liquid fuel purge air check valves. Failed liquid fuel check valves can also cause incomplete combustion and high exhaust temperature spreads. Severe problems can even result in loss of flame in one or more combustors (combustors with or without flame detectors) which can cause very high exhaust temperature spreads/trips. Low, high or uneven atomizing air flows can result in incomplete combustion and even loss of flame. Primary zone re-ignition or flashbacks in DLN combustors can cause high exhaust temperature spreads. Cracked or broken combustion liners or transition pieces, hula seal problems, and leaking transition piece side seals can result in high exhaust temperature spreads.

Some exhaust temperature spreads have been caused by insulation found to be blocking the air flow across the thermocouple. Improperly inserted- or terminated exhaust thermocouples can cause high exhaust temperature spreads immediately after a maintenance outage.

Finally, failed, failing or intermittent exhaust thermocouples can cause false exhaust temperature spreads and even trips. While commonly suspected at the first hint of exhaust temperature spread problems on running units, instrumentation problems are not usually to blame for exhaust temperature spreads unless wiring is damaged by heat or other causes. One way to quickly eliminate instrumentation issues is to change load appreciably. If the highest and/or lowest exhaust thermocouple readings do not move with load changes—meaning the position of the coldest (or hottest) exhaust thermocouple will change (“move”)—the cause may be attributed to failed or intermittent instrumentation. As was mentioned before, due to the swirl phenomenon a true exhaust temperature spread will appear to move (rotate; change position) as load changes; if the problem is one or two failed or failing exhaust thermocouples the position of the hottest/coldest thermocouple will not change with load.

MD&A Turbine and Generator Controls Division maintains a staff of OEM experienced field engineers who provide installation, technical support, advanced troubleshooting, training, and consulting services for gas turbine controls, generator excitation, and turbine auxiliary systems.

Call our MD&A Turbine and Generator Controls Division today at +1 (970) 224-2223 or use our Contact form.

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Mechanical Dynamics & Analysis (MD&A) Turbine and Generator Controls Division can recommission legacy gas turbine power generation control systems at a fraction of the cost of system replacement and can enhance these systems with a modern human-machine interface (HMI).

This recommissioning process can alert owner/operators to safety concerns, detect current and future nuisances or erroneous alarms, and build renewed confidence in asset operation through optimized control systems, alarms, and indications.

Recommissioning services and calibrations were recently completed, for example, on two GE^® Frame 7EA heavy-duty gas turbines with DLN-1 combustors, burning natural gas and used for peaking service. Both units utilize the Mark V turbine control system. Calibration check line-item pass/fail listings on these units showed device failure ratios of up to 30 percent.

The key to such work is focused precision along with full knowledge of the OEM system’s operations, hardware, and components.

Primary tasks are I/O loop-checking, function testing, and running checks while investigating all field devices, connections, and operating conditions. Improper equipment is either recalibrated or replaced.

Plant personnel offer input into the recommissioning and both their experience, efficiency, and safety are of utmost concern to MD&A. In a recent example, personnel expressed concerns over high turbine compartment temperatures. During recommissioning, MD&A’s investigators found non-working gravity-operated dampers and potentially high temperatures in the accessory compartment and around the turbine.

Both site personnel and MD&A also noticed loud buzzing in the 125 VDC battery chargers, indicating possible problems with the output filter capacitors and/or the main transformer. Loop-checking also uncovered numerous junction box issues that could severely impact the fire protection system.

This was in addition to the background that site personnel offered on nuisance and false alarms. Some field devices were found to be non-working and were replaced or readjusted, several inputs had not been originally connected to the Mark system, and general issues and long-term concerns were uncovered regarding conduits and circuit connections. Selected incorrect wiring was also discovered.

The key descriptors for MD&A’s Recommissioning Legacy Turbine Control Systems are meticulous attention to detail, pinpoint examination, in-depth problem solving, precise record-keeping and reporting, and full use of MD&A’s gas turbine knowledge and experience. And as a result, any alarms articulated during startup and operation should be reduced to only those that require attention.

MD&A recommissioning projects can be completed for as little as 10 percent of the cost of new or retrofit equipment with significantly less site and downtime and are available for any unit capable of being operated on cooldown, cranking, and starting and loading.

We are your full-service, OEM-alternative! MD&A Turbine and Generator Controls Division maintains a staff of OEM experienced field engineers who know and efficiently plan and execute the process, identify any issues and work with plant personnel on optimum resolutions. We provide installation, technical support, advanced troubleshooting, training, and consulting services globally for gas and steam turbine controls, generators, and auxiliary systems.

Contact our Turbine and Generator Controls Division to recommission your legacy turbine control systems at +1 (970) 224-2223 or use our contact form.

The post Recommissioning Legacy Turbine Control Systems for Enhanced Reliability appeared first on MDA Turbines.

MD&A’s Turbine and Generator Controls Division has a strategic partnership with Lectrodryer® to perform installation and commissioning services for their Generator Automated Hydrogen Purge Package.  When purchasing the Lectrodryer® hardware through MD&A, our experts can engineer the modification, remove the existing equipment, install the new equipment and integrate and commission the skid controls.

Hardware included:

• Lectrodryer® Automated CO₂ Purge Package including the Generator Gas Monitoring and Control (GMCP) Panel and the Generator Fast Degas CO₂ System (GFD) Skid
• Piping and Electrical installation materials

Service included:

• Engineering – Design of electrical connections and gas piping hook up based on agreed-upon equipment locations, including as-built one-line drawings.
• Craft Labor – Mechanical and Electrical Craft Labor as required to complete the installation and commissioning
• Technical Direction – Onsite engineer for the supervision of the equipment installation and commissioning.
• Calibration and commissioning of all Lectrodryer® equipment by MD&A and Lectrodryer®.

Most generators using this package can purge hydrogen to CO₂ in under one hour.

Give your plant the best possible solution with a minimum of oversight by combining the proven Lectrodryer® Generator Automated Hydrogen Purge Package with MD&A’s experience on generator auxiliary systems’ operation and maintenance.

MD&A’s Turbine and Generator Controls Division maintains a staff of OEM-experienced field engineers who provide installation, technical support, advanced troubleshooting, training, and consulting services for gas and steam turbine controls, generator excitation, and auxiliary systems.

Call our MD&A’s Turbine and Generator Controls Division today at +1 (970) 224-2223 or use our Contact form.

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MD&A has developed IBECS® to address these complexities. IBECS® is an HMI/SCADA system that integrates with many different platforms and provides a single place to control and monitor the entire power plant.

IBECS® is a powerful solution that simplifies power plant control and monitoring to provide the following benefits/features:

• Integrates multiple platforms in a single place
• Fully redundant (when two or more IBECS® HMIs are in service)
• Historical high-speed logging and trending
• Easy to configure graphics and displays
• Ability to perform diagnostics and monitor your process from anywhere
• Faster response time through native communication with control systems without the large created by third party communication protocols
• Advanced Connectivity (i.e. OPC, Modbus, DNP3, ODBC, etc.)
• Many more HMI/SCADA features

Eric Williamson, from the Cokenergy site, said:

“We replaced our existing GE® HMI with the IBECS® system.  Immediately we noticed it was so much easier to examine the code in the MarkV® using their interface software versus the old GE® software.  Instead of one rung at a time, and searching for items manually, we were able to see the rungs in a straight down format with click-searchable items which made for easier troubleshooting of issues.

The HMI side allows for more edits than the GE® side has.  We can monitor more points, as well as, add other systems to the same HMI system and be able to monitor/trend/control whatever we need to.  Overall, this system has helped us to not only keep the turbine online but prevent problems in the future by trending vibrations and temperatures.”

MD&A Controls Systems division maintains a staff of OEM experienced field engineers who provide installation, technical support, advanced troubleshooting, training, and consulting services for gas and steam turbine controls, generator excitation, and turbine auxiliary systems. Our experts offer turbomachinery consulting services, customized data collection, and analysis, along with complete start-up and commissioning support

For more information on IBECS®, call MD&A Turbine and Generator Controls Division today at +1 (970) 224-2223 or use our Contact form.

The post MD&A IBECS® – The Integrated Solution to Power Plant Control and Monitoring appeared first on MDA Turbines.

With a rich 40 years of experience in the power generation industry, Mechanical Dynamics & Analysis is the most trusted company for turbine-generator needs. 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 provides power generators around the globe with a full-service, OEM-alternative for services, parts, and repairs for Gas Turbines, Steam Turbines & Generators.

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.

Why should you opt for MD&A

With a vast years of experience, we are one of the largest non-OEM providers in the US, but our expertise reaches globally.

All of our team members – from project managers and engineers to our technicians, have seen and solved every challenge they have encountered. Our experts are capable of getting your equipment in top-notch working condition within the shortest possible span of time by coming up with the smartest and most effective solutions. Our team is always in close communication with our customers at every given moment – whether it is handling a major outage or even during routine service; our customers can depend on us at all times. Our innovative response in every situation has earned us trust in the industry. Our customers can count on us to work together to bring the right solution. That’s MD&A for you. Choose us. Choose right. One Call, One Source, Powerful Solutions!

Turbine Services

Whenever possible, power plant owners prefer to plan ahead for major turbine outages that involve turbine overhauls. However, forced turbine outages do occur and too often result in the need for expedited engineering response and immediate turbine outage services. MD&A provides clients with the labor, engineering, and the technical experts necessary to address both planned and forced outages of all types of turbines and generators. Our technical directors and project managers are available 24 hours a day for steam turbine services and gas turbine services.

Gas Turbine Repair and Service

MD&A is a full-service provider of gas turbine repairs and services. Our engineers strictly follow effective, time-tested principles that produce sound and superior repair solutions for gas turbine-generator rotors and components.

Our Turbine-Generator Repair Facility offers full capabilities for your gas turbine rotor maintenance and end-of-life assessment. It also has an elevator system to perform a full gas turbine rotor and compressor unstack and restack. Our talented and experienced team has full capabilities for blading, machining, re-bucketing, and more.

Types of gas turbines we repair

Fleet Support for: Alstom®: GT 8, GT 11, GT 13, GT 24, GT 26; General Electric®: Frame 3, 5, 6B, 6FA, 7EA, 7FA, 9E, 9FA; Siemens®: V84, V94

Gas Turbine Service

MD&A is an expert in providing assistance for forced or planned outages. Some of the gas turbine services we offer are:

• Outage Planning: Through knowledgeable and effective outage planning, outage times can be held to a minimum, thus maximizing your on-line time. With our Maintenance Advance Planning Services, we can meet your gas turbine service needs. Implementation of MAPS will serve to decrease your outage time and ensure you are back online at the earliest possible time.
• Technical Direction: Our project managers and technical directors specialize in the many unique and complex areas of turbine-generator engineering. They are extremely knowledgeable of all gas turbine parts and functions and gas turbine services. They have intricate knowledge of repairs, upgrades, overhauls and inspections. They have vast experience in the field and have worked on many different types of OEM equipment. This makes them the right choice for handling the most difficult technical problems.
• Turnkey Inspections: We provide turnkey solutions for your gas turbine. This includes Combustion Inspections, Hot Gas Path (HGP) Inspections, Major Inspections, Vane Pinning, and Generator Major & Minor Inspections.We have turnkey staff members who specialize in maintenance, testing, repair, inspection and training in over 20 countries across the world.
• Gas Turbine Alignment: Gas Turbine alignments pose unique challenges in alignment due to their large flexible cases that become distorted due to the severe operating conditions. MD&A’s laser alignment services provide customers with a reliable method of measuring and aligning gas turbine parts, including alignment of compressor discharge casings and exhaust frames during replacement.
• Coupling Laser Alignment: Aligning shafts using laser technology has increasingly become the preferred method of shaft/coupling alignment for many customers. Powerful laser equipment along with our technological expertise, make us your experts for solving all your aligning problems.
• Operational Alignment Diagnostics: MD&A’s Coordinate Measurement Machine (CMM) system allows us to measure and monitor large pieces of equipment during operation. Our experts are able to measure component positions and monitor their movements over time precisely. With this tool, we can properly identify the gas turbine parts that have operational problems because of thermal growth, vacuum deflection, deflections due to piping forces or movement issues with equipment.
• End of Life Evaluation: Statistical predictions of component life can be the basis of gauging the end of life (EOL) a gas turbine rotor. A proper assessment by our experts can decide if component Repair, Replace or Use is the best option for your gas turbine rotor to meet operational and maintenance forecasts.
• Field Machining: MD&A offers an array of portable field machining and steampath repair equipment for use on-site. We also maintain portable machine shops that can be rented by clients for general outage use. Our machining capabilities include the ability to on-site or in-shop repair horizontal joints on turbine casings, damaged valves, rotors and nearly any rotating or stationary turbine-generator component.
• Balancing and Vibrational Analysis: MD&A’s on-site vibration and balance experts are experienced in using a variety of vibration analysis equipment with 24-hour emergency service and on-site low-speed balance. Our modern High-Speed Balance Facility was designed with both vacuum capability and the ability to excite generator rotors at high-speed, allowing the testing and balancing of both gas turbines & steam turbines and generator rotors.
• Control and Excitation Field Engineering Consulting and Training: Our engineers are experienced in installation, advanced troubleshooting, technical support, training and consulting services for your gas turbine controls, generator excitation, and turbine auxiliary systems.
• Thermodynamic Analysis: To improve the cycle performance, MD&A provides Thermodynamic Analysis services for customers. This helps to predict the off-design performance of the cycle. The performance for a new cycle or a cycle with new components can be predicted to make better decisions on cycle arrangements to optimize efficiency. Our Thermographic Surveys can be taken by customers as a standalone service or it can also be a part of our performance testing analysis service.
• Performance Testing & Analysis: We provide a variety of performance testing and analysis solutions on the basis of the plant’s overall test objective. Our gas turbine engineering focus is to assess the thermodynamic condition of your gas turbine and gas turbine parts in the cycle.

Steam Turbine Repair and Service

MD&A is a full-service provider of steam turbine repairs and services. We have been providing steampath turbine repairs services for over four decades.

Our engineers make steam turbine repair recommendations based upon the owner’s intended operating plans for the unit. We maintain a staff of experienced full-time steampath engineers who specialize in the engineered repair of stationary and rotating components.

Whenever possible, power plant owners prefer to plan ahead for major turbine outages that involve steam turbine overhauls. However, forced steam turbine outages do occur and too often result in the need for expedited engineering response and immediate turbine outage services. MD&A provides clients with the labor, engineering and the technical experts necessary to address both planned and forced outages of all types of turbines and generators. Our technical directors and project managers are available 24 hours a day.

Parts of steam turbine that can be repaired

We offer repair services for steam turbine parts like steampath components, stationary components, valve components and many more parts. Our mechanical engineers are experienced and skilled & provide expedited engineering response to our clients.

Our steam turbine parts solutions address reliability, life extension and capacity demands. Load demand, financial pressures and aging steam turbine generators have created the need to extend longevity and reliability.

Steam Turbine Service

MD&A provides clients with the labor, engineering and the technical experts necessary to address both planned and forced outages of all types of steam turbines and generators.

• Outage Planning: Through knowledgeable and effective outage planning, outage times can be held to a minimum, thus maximizing your on-line time. With our Maintenance Advance Planning Services, we can meet your steam turbine service needs. Implementation of MAPS will serve to decrease your outage time and ensure you are back online at the earliest possible time.
• Technical Direction: Our project managers and technical directors specialize in the many unique and complex areas of turbine-generator engineering. They are extremely knowledgeable in steam turbine parts and functions and steam turbine services. They have intricate knowledge of repairs, upgrades, overhauls and inspections. They have vast experience in the field and many OEM equipment. This makes them the right choice for handling the most difficult technical problems.
• Topless Alignment: Our Topless Alignment Services® eliminates the time consuming and expensive process of reassembling the steam turbine for “Tops-On” measurements, saving hundreds of man-hours and labor per turbine section. Most centerline alignment activities are moved off the critical path, reducing outage duration by days.
• Coupling Laser Alignment: Aligning shafts using laser technology has increasingly become the preferred method of shaft/coupling alignment for many customers. Powerful laser equipment along with our technological expertise, make us your experts for solving all your aligning problems.
• Operational Alignment Diagnostics: MD&A’s Coordinate Measurement Machine (CMM) system allows us to measure and monitor large pieces of equipment during operation. Our experts are able to measure component positions and monitor their movements over time precisely. With this tool, we can properly identify the steam turbine parts that have operational problems because of thermal growth, vacuum deflection, deflections due to piping forces or movement issues with equipment.
• Custom Installation of Seals: MD&A offers tailor-made installation of any packing ring or tip seal. With the help of a mobile containerized machine shop, our steam turbine parts experts offer the best quality installation in the industry. This ensures that the seal is properly installed and functions as required.
• Field Machining: MD&A offers an array of portable field machining and steampath repair equipment for use on-site. We also maintain portable machine shops that can be rented by clients for general outage use. Our machining capabilities include the ability to on-site or in-shop repair horizontal joints on turbine casings, damaged valves, rotors and nearly any rotating or stationary turbine-generator component.
• Balancing and Vibrational Analysis: MD&A’s on-site vibration and balance experts are experienced in using a variety of vibration analysis equipment with 24-hour emergency service and on-site low-speed balance. Our modern High-Speed Balance Facility was designed with both vacuum capability and the ability to excite generator rotors at high-speed, allowing the testing and balancing of both gas turbines & steam turbines and generator rotors.
• Control and Excitation Field Engineering Consulting and Training: Our engineers are experienced in installation, advanced troubleshooting, technical support, training and consulting services for your steam turbine controls, generator excitation, and turbine auxiliary systems. Our engineers specialize in Mechanical Hydraulic (MHC) and Electro Hydraulic (EHC) Controls, including GE® MKI through MKVIe systems.
• Steam Path Audits: A steam path audit is a physical inspection of the turbine steampath, conducted while the rotor is on the half-shell. The purpose is to identify and quantify performance problems of the steam turbine due to the deterioration of steampath components. Engineers and maintenance personnel use the results of audits to identify the most cost-effective repairs and to justify repair recommendations. We offer both thermodynamic and structural audits.
• Turbine Engineering: In the field of steampath engineering services, we are leading suppliers for the service of steam turbines. Our personnel is experienced and are on-site always. They are factory trained with extensive OEM field experience before joining our team.
• Remaining Life and Finite Element Analysis: MD&A leads the power generation industry with computer engineered solutions that address issues associated with an aging steam turbine fleet. We use finite element analysis to precisely model steam turbine parts and determine the root cause of component issues and to evaluate the remaining life shells, steam turbine rotors parts, valves and other integral steam turbine parts subject to high thermal stress factors.
• Thermodynamic Analysis: To improve the cycle performance, MD&A provides Thermodynamic Analysis services for customers. This helps to predict the off-design performance of the cycle. The performance for a new cycle or a cycle with new components can be predicted to make better decisions on cycle arrangements to optimize efficiency. Our Thermographic Surveys can be taken by customers as a standalone service or it can also be a part of our performance testing analysis service.
• Performance Testing & Analysis: We provide a variety of performance testing and analysis solutions on the basis of the plant’s overall test objective. Our gas turbine engineering focus is to assess the thermodynamic condition of your steam turbine and steam turbine parts in the cycle.

Gas Turbine Parts & Steam Turbine Parts

Our MD&A Parts Division is a premier worldwide supplier of replacement steam and gas turbine parts and components. Specializing in the manufacture and supply of turbine parts such as packing rings and spill strips, we can also offer a variety of other non-rotating steam and gas turbine parts, from fasteners to valves.

Additionally, MD&A’s San Antonio Service center offers gas turbine parts, repairs, and upgrades.It has cutting edge equipment to handle all your gas turbine parts.

Our team has extensive knowledge for a range of gas turbine component repairs, including weld repair, blend repair, dimensional restoration, and machining. Our expert technicians are well trained, seasoned professionals with in-depth knowledge of the many strict tolerance, procedures, and specifications to complete each repair.

Our Turbine-Generator Repair Facility repairs gas turbine parts. MD&A offers competitive turbine parts solutions for addressing reliability, life extension and capacity demands by providing retrofit and turbine part solutions for large steam turbine-generators. Load demand, financial pressures and aging steam turbine generators have created the need to extend longevity and reliability. Our turbine parts upgrades capture the latent potential of power plant auxiliary systems and retain thermal performance, providing a cost-effective recovery and enhancement of turbine efficiency.

We are trusted by users across the world because we are capable of solving every conceivable need – be it steam turbines, gas turbines or generators.

For more information call MD&A today at +1 (518) 399-3616 or use our Contact form.

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This practice has allowed the customer to optimize their unit’s operational availability while reducing their maintenance costs. The predictive approach allows savings to be realized by avoiding unnecessary periodic maintenance while assuring component integrity, thereby avoiding episodic maintenance due to in-service failures which often result in forced outages. This service is available for all types of steam turbine servo controlled actuators on fossil-fired, industrial, and combined cycle units.

Currently, no regulatory maintenance practices or intervals have been specified in the United States for non-nuclear steam turbine valves and actuators. Typically, we have seen OEM’s, Non-OEM’s and other industry organizations recommend minimum maintenance intervals for steam turbine valve inspection and repairs every three (3) to five (5) years. Some say these inspections and repairs should occur, as a minimum, every 25,000 Effective Operating Hours (EOH).

Adopting a data-driven approach to condition analysis will produce the following beneficial results when compared to strictly periodic maintenance:

• Understanding of, and insight into, the asset’s current operating performance

• Awareness of life expectancy predictions for individual system components

• The time and confidence to plan and optimize downtime

• The ability to focus on and manage costly repairs before they are required

To further describe the steam turbine valve actuator diagnostics service performed, we started off by recording valve motion data from each of the customer’s Control Valves, Main Stop Valves, and Intercept Valves. Each of these valves had servo modulated position control capabilities and were opened and closed at a rate of 3% per second. Data was gathered for servo coil voltage and demodulated position feedback voltage.

Individual valve hysteresis test results for each valve were then graphed.  There were no concerns of mechanical problems with the hydraulic cylinders on the control valves and intercept valves.  As shown in the graph for one of the main stop valves below, observations made by MD&A’s controls engineer indicated that the measured servo coil voltage ramp rate showed anomalies. The slope changes indicate the actuator cylinder is either leaking or sticking.

Our recommendations included further investigation of main stop valve 2 within the next year, and the hysteresis test should be performed again to confirm the anomaly is repeatable.

The cost savings associated with this type of predictive analysis can be substantial. Maintenance on a high-pressure positioning actuator typically ranges from $20,000 to $30,000, including removal and re-installation costs. If the actuators on an averaged size turbine are found to be in good condition as a result of the analysis, savings could be well over $200,000.

MD&A’s Turbine and Generator Controls Division maintains a staff of OEM experienced field engineers who provide installation, technical support, advanced troubleshooting, training, and consulting services for gas and steam turbine controls, generator excitation, and auxiliary systems. Call our MD&A Turbine and Generator Controls Division today at +1 (970) 224-2223 or use our Contact form.

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The post Steam Turbine Valve Actuator Diagnostics for Predictive Maintenance appeared first on MDA Turbines.