{"id":74833,"date":"2025-02-18T14:37:49","date_gmt":"2025-02-18T19:37:49","guid":{"rendered":"https:\/\/www.mdaturbines.com\/?p=74833"},"modified":"2025-02-18T15:57:57","modified_gmt":"2025-02-18T20:57:57","slug":"main-stop-control-valve-and-bucket-replacements","status":"publish","type":"post","link":"https:\/\/www.mdaturbines.com\/resources\/main-stop-control-valve-and-bucket-replacements\/","title":{"rendered":"Main Stop Control Valve and Bucket Replacements"},"content":{"rendered":"

MD&A performed a major inspection and scheduled repairs of a Toshiba\u00ae 130 MW steam turbine<\/a>. During this planned outage, along with a LP turbine inspection, the combined main stop\/control valve (MSV\/CV) was replaced, as well as the L-0 and L-1 buckets.<\/a><\/p>\n

MSV\/CV <\/strong>Replacement<\/strong><\/p>\n

Replacement of the combined main stop \/ control valve (MSV\/CV) was requested by the customer in response to a technical memo issued by the OEM relating to a material deficiency. The valve\u2019s original body was a casting, which is prone to stress fatigue and cracking. As a result, the OEM recommended that the valve be replaced with one that has a forged body.<\/p>\n

MD&A\u2019s experts completely replaced the combined main stop and control valve assembly.<\/a> The team provided engineering services for the MSV\/CV replacement and outlet pipe modification work to accommodate the new valve assembly.<\/p>\n

A new monorail beam was installed to facilitate future CV actuator removal.<\/p>\n

After installation, MD&A\u2019s technicians performed several tests and inspections on both main stop and control valves to verify proper installation and assembly. \u00a0They also performed HP shell arm loading tests before and after the valve assembly was replaced. Radiography inspections were also conducted after the valve casing was installed, revealing some deficiencies that were remedied immediately.<\/p>\n\n\n\n
\n

\"old
Old MSV\/ CV body<\/figcaption><\/figure><\/td>\n
\n

\"main
New Valve Casing in place<\/figcaption><\/figure><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

LP Rotor Inspection, Bucket Replacement, and Related Repairs<\/strong><\/p>\n

As part of planned work for this outage, MD&A’s experts removed and shipped the steam turbine LP rotor to MD&A\u2019s Turbine-Generator Repair Facility<\/a> for inspection and bucket replacement (which had been previously recommended by MD&A\u2019s major inspection of the unit in 2020). The team performed visual inspection, blast cleaning, dimensional inspections, and NDE inspection of the entire rotor.<\/a> The rotor was found to be in very good condition overall. Steampath inspection revealed minor FOD, minor moisture erosion, and minor rubs on packing seal lands.<\/p>\n

MD&A\u2019s experts installed new buckets<\/a> for rows L-1 and L-0 rows, according to the moment weight chart provided with the buckets. They required replacement due to wet steam erosion and OEM TIL recommendations.<\/p>\n

Rather than replacing them with conventional components, our Advanced Continuous Cover Blades<\/a> (CCB) were utilized. These blades are constructed using a mono-block blade structure, leaving fewer locations for corrosive deposits. They are less susceptible to stress corrosion cracking and demonstrate excellent vibration characteristics. These long blades provide up to 8% stage efficiency increase, without requiring diaphragm replacement. As part of their installation, MD&A\u2019s technicians reamed all dovetail pinholes, and installed new pins.<\/p>\n

After installation, covers for both stages were final machined as required to meet the stated requirements. The team also conducted minor repairs for stages 13 TE & GE to resolve FOD\/impact airfoil damage.<\/p>\n

Upon completion of the work, a high-speed balance<\/a> of the rotor was performed at our Repairs Facility.<\/p>\n

\"High-Speed
High-Speed Balance<\/figcaption><\/figure>\n

Once the LP inner casing<\/a> was removed, NDE inspection was performed on the struts located in the center flow area to verify the strut repairs from a previous outage. The LP inner casing horizontal joint was also inspected, and minor erosion was found on the upper half. During reassembly, high temperature sealant was used in the eroded area.<\/p>\n

IP & LP Admission Control and Stop Valves were also disassembled and inspected during the outage.<\/p>\n

Lastly, at startup, a vibration analysis<\/a> was performed and the vibration levels were found to be low and met the requirements for acceptable operation.<\/p>\n

CV and IP Admission Actuator Repairs<\/strong><\/p>\n

As part of the planned outage, MD&A\u2019s team removed one Rexroth\u00ae Extraction CV actuator<\/a>, two Mafag\u00ae IP admission valve actuators, and two Mafag\u00ae LP admission valve actuators. \u00a0They were shipped to MD&A\u2019s Bearing, Seals and Hydraulics facility<\/a> for disassembly, inspection, repair, reassembly, and testing.<\/p>\n

\"Cylinder
Cylinder & Spring Can<\/figcaption><\/figure>\n

For the CV actuator, our experts rebuilt the servo, and tested, flushed, reinstalled the poppets, and replaced shaft seals and O-rings. All other main components of the actuator were found to be in good condition and reused.<\/p>\n

\"New
New CV Actuator<\/figcaption><\/figure>\n

For the IP and LP admission valve actuators, our technicians performed various repairs including chroming and grounding two of the shafts, polishing two of the cylinders, replacing a poppet valve on one unit, and installed new RVDT and packing glands on all.<\/p>\n

Upon completion of reassembly, all actuators were tested and found to be properly functioning and free of leaks. The actuators were pressure tested at 110% and stroked and tripped several times.<\/p>\n

Bearing, Seals and Hydraulics experts also repaired the T4 bearing because onsite the upper half bearing showed indications of lack of babbitt bonding at the horizontal joint. They blended some babbitt and additional PT was performed with no indications found.<\/p>\n

Controls<\/strong><\/p>\n

MD&A\u2019s technicians performed a wiring inventory of the DEHC and distributed IO channels. Several observations were made including old wiring that should have previously been removed, and issues with wiring that was not wired to the manufacturer\u2019s documented specifications. The shields for four RVDT position feedback triad cables were also not landed at the EHC cabinet. MD&A\u2019s technicians worked with the on-site electrician to resolve these issues.<\/p>\n

The team also noted that the CV junction box did not have a properly connected ground cable. Further, LVDT jumper settings in the EHC cabinet were found in to be in \u201cas-shipped configuration\u201d, and therefore not properly configured. MD&A\u2019s team<\/a> resolved the issues by adjusting the settings to match the manufacturer\u2019s drawings.<\/p>\n

Summary<\/strong><\/p>\n

The extensive scope and successful completion of this engagement demonstrate MD&A\u2019s ability to provide expert service on a wide range of steam turbine systems and components. From inspection and routine repairs, to more extensive work, such as Main Stop Control Valve and Bucket Replacements, MD&A\u2019s technicians completed the work on time and to the customer\u2019s satisfaction. This case perfectly demonstrates why MD&A is respected as a full-service, one-stop source for turbine operators worldwide. Call our us at (518) 399-3616 or use our Contact Form<\/a>.<\/p>\n","protected":false},"excerpt":{"rendered":"

MD&A performed a major inspection and scheduled repairs of a Toshiba\u00ae 130 MW steam turbine. During this planned outage, along with a LP turbine inspection,…<\/p>\n","protected":false},"author":13,"featured_media":74839,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"content-type":"","footnotes":""},"categories":[3,209],"tags":[317,107,77,195],"class_list":["post-74833","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-mda-insight","category-steam-turbine","tag-control-valve","tag-controls","tag-steam-turbine","tag-turbine-buckets"],"acf":[],"yoast_head":"\nMain Stop Control Valve and Bucket Replacements – MDA Turbines<\/title>\n<meta name=\"description\" content=\"MD&A performed Main Stop Control Valve and Bucket Replacements during scheduled repairs of a Toshiba\u00ae 130 MW steam turbine.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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