Outage Services Capabilities

The Turbine-Generator Engineering & Outage Services Company

Outage Planning
Pre-Outage Planning
Pre-outage planning can begin up to 18 months prior to an anticipated outage. This involves a review of the specific units outage and operating history using customer-provided documents. The review incorporates the anticipated outage dates, past outage reports, interviews with client personnel, as well as fleet and outstanding OEM maintenance recommendations. Currently available parts and materials are inventoried by either MD&A or the client and used in the outage planning process. The objective of pre-outage planning is to develop a list of needed equipment, tasks, and parts to be included in the final outage plan. This review identifes services, such as safety orientations, steampath inspections, performance evaluations, vibration services, alignment services, and shop services that must later be incorporated into the outage plan. The result of this review becomes a draft document reflecting equipment and service needs, objectives to be accomplished, and the parts or materials available and needed. This information becomes a working document used in the next phase of MAPS, outage planning.

Our MAPS program provides owners with an experienced engineer who helps to guide and plan your next scheduled outage while taking into account past outage reports, parts inventories and other resources necessary to meet the outage objectives.

Outage Planning
Outage planning typically starts 6 to 8 months before the outage date and is a direct extension of preoutage planning activities. The objective of outage planning activities is to establish a final list of known and potential outage activities, work scopes and a flexible schedule that includes verifying the availability of needed services, parts and materials. This work scope includes all major tasks broken down into sub-activities. The objective and sequence of work to be performed is defined and plotted. Activities not included but that may be added as circumstances dictate are identified and listed as potential additional work scope items. This document contains the full scope of the customers outage needs and can be used to develop the bid package sent to vendors and/or is used in pre-bid discussions. Our MAPS engineer can also provide guidance in the development of proposal requests to specific service vendors.

Post-Outage Review
If desired, a post-outage review can conducted. The review consists of a comprehensive analysis of the outage, identifying the achievement of milestones, added and deleted activities, parts used, and recommendations for the next planned outage. Open items and issues are identifi ed and a resolution or action proposed. The result of this review becomes a key element in preparing the next pre-outage plan. The fi nal MAPS report becomes not only an important list of recent and past outage activities but also a future to-do working document that is passed on refl ecting both historical activities and anticipated future resources. MAPS will take much of the guess work out of planning your next outage and save both time and funds.

For more information on MD&As products and services please call (518) 399-3616. Visit us on-line at www.MDAturbines.com

Life Assessment & Failure Analysis

MD&A offers a comprehensive array of engineering services which determine the remaining life of components and the root cause of failures in heavy rotating machinery. We provide written evaluations along with lab results when offering solutions that correct the underlying problem, rather than merely providing a temporary repair. Our services thereby reduce the need for continual rework and eliminate or reduce recurring maintenance costs. MD&A uses in-house engineering analysis (FEA, creep and crack growth calculations) as well as extensive historic OEM and project experiences to determine the source of problems and to evaluate viable solutions. Our recommendations focus on either extending the operating life of the component in its current condition or evaluating the life extension associated with repairs. We present you with viable options and help you determine the benefits of each option versus the cost. Some options may be short term and less costly while others offer permanent solutions.
Lab photo of low cycle fatigue crack originating on ID of the steam chest of a General Electric steam turbine.

An abbreviated list of Life Assessment Services offered by MD&A includes:

COSMOS FEA and Solidworks 3-D software are used here on a GE steam chest to determine operating stress levels and areas prone to fatigue and creep.

Finite Element Analysis to determine weak areas and operating stresses Evaluation of the current condition of your plant and steam cycle components Determining the effect of increasing temperatures and pressures on components Assessing the effects of higher turbine and generator output on units being repowered for combined cycle or cogeneration service Quantifying the severity of transients resulting from future start-ups Determining the number of start and shutdown cycles before repairs most likely will be required on rotors using SAFER software (for EPRI Members) Steam temperature ramp rate optimization Recommendations for more efficient load change rates as compared to OEM S&L charts Evaluation of creep in turbine casings, valve bodies and other components Determining the operating limits for startup transients Quantifying the effects of operating history on component life Assessment of defective components Calculating crack growth rates for stationary turbine components Evaluating stress data, material properties and NDE defect information
On-site welding of GE steam chest / upper and lower valve body following disassembly and repair to correct for creep damage in OEM weld.

GE steam chest after repairs and design upgrade to correct OEM weld design defects.

For more information on MD&As products and services please call (518) 399-3616. Visit us on-line at www.MDAturbines.com

Turnkey Outage Services

Turnkey Outage Services

MD&As proven competence at providing the full range of resources needed to fully service turbine-generator equipment from all manufacturers has made us one of the largest and most reputable turnkey service providers in the United States. From disassembly to inspection, assessment and repair to full restoration and start-up, MD&As turnkey inspection services are available for the full range of OEM equipment types, output and designs. As a standard component of any turnkey service, MD&A supplies the necessary skilled craft labor force and experienced supervision, together with specialized tools, equipment and precision measuring devices needed for any turbine-generator overhaul.

MD&A crews installing a double-flow LP rotor following a recent turnkey turbine inspection project.

As specified by the client, our services may include the following:

MD&A supplies a complete mobile inventory of specialized turbine tools for off-loading at job sites.

Outage scope development and planning Project management (from pre-planning to start-up) Computer aided scheduling and cost reporting systems Experienced craft labor Field technical direction and project management Mobile inventories of specialized tools and equipment On and off-site services for turbines and generators Replacement parts and restored components Equipment engineering for turbines and generators Controls and start-up engineering Balancing and unique topless laser alignment procedures Grit blasting and NDE services Safety and drug testing programs Labor relation services

Disassembly work in progress prior to a turnkey air-cooled generator test and electrical inspection conducted by MD&A personnel.

MD&As turnkey approach provides clients with immediate access to all of MD&As resources and services; it maximizes project efficiency, streamlines communication, and provides clients with a single source of accountability.

Final re-assembly of a Westinghouse turbine-generator set following a turnkey inspection at a southern utility in the United States.

For more information on MD&As products and services please call (518) 399-3616. Visit us on-line at www.MDAturbines.com

Technical Direction & Project Management

MD&A is renowned in the power generation industry for an outstanding and diversified staff of Field Engineers. For power plant owners conducting turbine and generator inspections, overhauls, repairs and upgrades there is no better source than MD&A for technical expertise. Our on-site TDs have full access to all MD&A technical assets, including personnel within other divisions of the company needed to address unexpected engineering challenges arising during an overhaul. On average, all MD&A field engineers have no less than 10 years of experience and nearly all come from extensive technical backgrounds and disciplines. Likewise, many of our Field Engineers join the organization with significant customer-specific experiences and years of established and trusted relationships with utility personnel. This broad background, experience with design, installation and operation of OEM equipment and historic project experience are the key elements that enable our engineers to effectively address even the most complex technical challenges. Undoubtedly, MD&A provides some of the finest and most knowledgeable Field Engineers and Project Managers in the world.

MD&As Project Managers have the experience necessary to control all aspects of your utilitys turbine-generator repair, upgrade or inspection. From scheduling of repairs to management of millwright crews, MD&A has the many years of experience needed to run your outage smoothly and provide the depth of resources needed to quickly address unexpected technical issues not found within the original outage scope.

An abbreviated list of the services provided by our Field Engineers includes:

On-site critical path scheduling using MS Project or Primavera 5 Control of outage activities Coordination of outage teams Supervision of rigging and crane operations Updated progress reports and schedule revisions Review of turbine-generator drawings Comprehensive outage documentation Preparation of outage activity details and tracking reports Technical opinions and repair recommendations Scheduling and coordination of sub-contractor work Receiving of tools and test equipment Access to other field engineering resources Supervision of data collection

MD&As Technical Directors provide utilities with the valuable perspective of an engineer who has spent numerous years involved in identifying the issues and drafting the solutions associated with specific unit configurations and mechanical issues. Not only are our Technical Directors experienced, many wrote the book on repair methods employed today.

For more information on MD&As products and services please call (518) 399-3616. Visit us on-line at www.MDAturbines.com

Topless Laser Alignment

MD&As topless alignment method has been used successfully on over 900 turbine sections. Machines have ranged in size from 40 to 1200 MW. Unit restarts have been remarkable for their lack of rubbing during start-up and operation.

A partial list of the benefits of topless alignment includes:

Hand held laser centerline reading tool can read any bore measurement needed and allows for fast and accurate data acquisition.

No surprises, all alignment moves defined by 2nd week of outage Reduced outage duration Saves about 300 man-hours per turbine section by not performing a tops on movement Opening coupling checks are done with LP hoods off, allowing earlier LP disassembly Upper and lower shells are only needed for one shift per section to measure distortion Stationary component alignment is done off critical path Bearing shim changes and pad contact checks are done off critical path Elimination of startup rubbing maintains as-assembled internal clearances
The alignment laser beam is tracked at all times by a reference target that is set within the bearing bore.

A long line is taken through all turbine sections immediately after rotors are removed. This line is used along with opening coupling checks to calculate the ideal rotor alignment. Stationary component and bearing alignment can then be done off critical path while repairs are being made. Final coupling checks are done after final assembly, typically with only a few bearings requiring changes. If required, shim changes are typically less than .010 and bearing pads do not require re-bluing.

MD&As precision laser levels are used to measure the exact details of distortion on horizontal joints of the turbine casing.

Initial Laser Line Readings

Laser line readings require about six hours per turbine section; they are taken during disassembly, immediately following rotor removal, during slack time while the stationary components are waiting for rotors to be blast cleaned. Initial component moves can then be done as a non-critical activity while the components are being repaired. Final alignment is verified, and corrected if necessary, after component repairs are completed.

Bore roundness data is taken by the alignment engineer without the need to assemble the upper and lower half components.

For more information on MD&As products and services please call (518) 399-3616. Visit us on-line at www.MDAturbines.com

High Quality Parts & Components

Turbo Parts
Phone: 518-885-3199

Turbo Parts is well established as a leading provider of highquality turbine and generator components. Product capabilities range from the patented Guardian Packing and Vortex Shedder sealing system for improved turbine efficiency to custom engineered stationary and rotating turbine-generator components for nearly all makes and models of machines.

Vortex Shedders create a pressure barrier at the seal tooth, lowering the delta-P across the seal. Lower pressure drops mean less steam leakage.

Components include, but are not limited to:

High pressure valve components of all types Stationary seal components for all models of steam turbines Components for generator fields and stators Components for front standards such as pistons and worm wheels Steam turbine blades and buckets Auxiliary equipment for generators such as skid components Retaining rings, fan blades, brush holders and collector rings

During rub conditions Guardian Packing Posts contact the rotating shaft first, preventing damage to the conventional seal teeth and preserving steampath efficiency.

Renewal Parts Maintenance

Phone: 440-946-0082

RPM, a division of Mechanical Dynamics & Analysis, is a leading manufacturer of steam turbine and generator bearings and seals. Years of satisfying clients has earned RPM the reputation of The Industrys Leading Tapered Land Thrust Bearing Specialist. As a specialty service provider, we also have a reputation for offering exceptional consultation on all matters pertaining to bearing diagnostics, maintenance and repair. RPM offers technical direction, start up assistance and installation service for all the components we manufacture and refurbish. At RPM, we strive to provide our clients with the highest quality bearings, seals and service available anywhere in the power generation industry.

Renewal Parts Maintenance has earned the reputation as The Industrys Leading Tapered Land Thrust Bearing Specialist by providing clients with the highest quality bearings and seals available anywhere.

RPMs complete reconditioning of hydrogen seal housing areas assures that all components fit together before they are shipped to clients and reduces the potential labor needed for assembly in the field.

For more information on MD&As products and services please call (518) 399-3616. Visit us on-line at www.MDAturbines.com

Valve Repair Services

MD&A provides inspection, repair, restoration, replacement parts and upgrades of high-pressure valve and valve components. Facilities are located at central locations within the United States. We provide re-engineering and manufacturing of valves from all manufacturers and address OEM design-flaws. In-house engineering, welding, heat treating and replacement part sources gives you one stop shopping and piece of mind. This eliminates the need for constant re-work each outage. All MD&A valve work performed comes with a minimum one-year guarantee.

Automatic orbital TIG welding on worn governor valve seats. Faster than conventional methods and the highest quality available.

Valve inspection services include:

Turnkey disassembly of valves and actuators On-site inspection by factory-trained engineers Grit-blast cleaning and NDE of surface areas Check for fatigue and creep damage Perform runout, detailed dimensional checks and blue contact checks Conduct valve lift checks Provide a written condition report with recommendations

Automatic orbital welding equipment shortens schedule and increases quality. Flex gasket installation preparation shown here.

GE Valve repair services include:

Repair/replacement of stems, disks, seats, bushings, etc. Repair/replacement of shafts, cams and casings Replacement of fine and course mesh screens Weld and machining repair for cracking, distortion and erosion Replacement parts (studs, nuts and washers) Weld restoration of Stellite and other sealing surfaces
Custom designed tooling allows center seat and valve casing machining in one fast setup.

For Westinghouse Throttle and Governor Valves:

In-plant weld repairs with valves in place Eliminate stud hole thread damage Eliminate early roll-off with New Pilot Valve Design Upgrade to flex gasket types, elimination of Refractalloy bolting needs Repair of steam dam and trepan groove cracking Replacement parts (stems, bushings, seats, disks, studs, nuts, etc.) Correction of loose seat fits In-place refurbishment of seats with Stellite overlay Restoration of enlarged GV bushing bores In-house automatic orbital TIG & GMAW welding Precision portable field machining

Orbital welding equipment decreases repair time to governor valve bushing bores and sealing surface, while providing a uniform bead.

For more information on MD&As products and services please call (518) 399-3616. Visit us on-line at www.MDAturbines.com

Balancing and Vibration Analysis

MD&A has, since its founding in 1982, enjoyed a reputation throughout the power industry as a company employing innovators, practitioners and teachers in the art of balancing and vibration analysis of heavy rotating equipment. In fact, the industry standard one shot balance method was developed by the founder of MD&A. MD&A is one of the leading proponents and developers in the use of influence coefficient balance methods, a method which offers the best assurance of reliable results. Over many years, MD&A has taught balance and vibration analysis courses and technical sessions to a wide range of our customers within the US, many on a repeat basis. Course materials have covered the fundamentals, data taking, use of analyzers, equipment characteristics, strategies for handling vibration problems and have even included the details necessary to conduct balance work as a profession. Equally as important as knowing where to place the balance shot is the ability to identify the source of related problems such as oil whip, rubbing or bearing issues. It is this added ability of our engineers to assess non-vibration issues that sets MD&A apart from our competitors in the field. Today, MD&A maintains a wide range of vibration analysis equipment that remains readily available, permitting our engineers to perform accurate and rapid data acquisition on your machine when an emergency arises. Our data acquisition equipment is capable of direct transfer to a computer and uploading directly via modem for display, editing and analyses. MD&As staff of on-site balance and vibration experts are highly experienced at in-place balancing, coming from a range of OEM and utility company backgrounds. MD&A also offers on-site low-speed balance services for rotors weighing up to 400,000 pounds. We maintain both stationary and portable balance machines at various locations around the United States. These machines, together with trained technical staff and seasoned balance engineers, allow us to address any balance job quickly. Low-speed balance of turbine rotors is an art, requiring careful review of data and a historic perspective that only comes from experience. MD&A also offers high-speed balance for turbine and generator components upon request.
MD&As vibration experts are available to provide guidance for the installation and maintenance of turbine supervisory instrumentation.

MD&As engineers provide vibration analysis and modal resonance testing to identify the components natural frequency characteristics.

Photo shows a low pressure steam turbine rotor being lowered onto portable low-speed balance equipment at a mid-west utility.

Our engineers use the latest in state-of-the-art equipment such as the Turbo-Balancer to quickly record data in digital format for easy transfer and remote analysis.

For more information on MD&As products and services please call (518) 399-3616. Visit us on-line at www.MDAturbines.com

Control Systems
MD&A Control Systems is located in Fort Collins, Colorado. The company was founded as NovaTech, Inc. in 1983 to offer the power generation industry an alternative to OEM turbine-generator controls services. Today, as a division of Mechanical Dynamics & Analysis, MD&A Control Systems offers a complete range of products and services on turbine and generator controls and auxiliary systems, from preventive maintenance calibration to complete system upgrade replacements. As control system specialists, MD&A offers products and technical support for the following systems:

EHC High Pressure Fluid System: vertically mounted, ultraresponsive Parker hydraulic pumps allow this upgrade, designed by MD&A, to resolve the problems created by the slow response time of the original OEM provided pumps.

Steam Turbine Controls:

Mechanical Hydraulic Controls - All turbine types Electro-Hydraulic Controls - Large Steam Turbine through MKIIA, Medium Steam Turbine though MKIII and Mechanical Drive Turbine through MDT-80

Hitachi VCS-6000 Excitation System

Hitachis VCS-6000 state-of-the-art excitation system includes a digital automatic voltage regulator and power system stabilizer. The VCS-6000 is highly adaptable as a retrofit upgrade / replacement system and can be used in a small rotating or large static excitation application.

MD&As Control Systems engineers provide clients with custom engineered control systems solutions, addressing recurring issues and reducing time-consuming trial and error attempts to correct problems.

Turbine-Generator Auxiliary Systems:

High Pressure Hydraulics Lubrication Oil Steam Seal Hydrogen Seal Oil Stator Cooling and Gas Control

MD&As proprietary Control System Life Extension upgrade enhances existing circuit boards and power systems by resolving issues associated with the original MK I & II power supplies, such as drift, instability, and capacitor leakage.

MD&A also offers control system life extension, preventive maintenance and digital upgrades for:

Turbine Controls Electro-Hydraulic and Mechanical-Hydraulic Turbine Auxiliaries Hydraulic, Lube Oil, Supervisory Generator Voltage Regulators Brushed and Brushless Generator Auxiliaries Hydrogen Seal, Gas Control HMI Analog/Digital Conversion, DCS Interface Instrumentation Maintenance Advanced Planning Services

MD&As TCX system upgrades and converts your existing control system using PLC hardware and digital human-machine interface (DHMI) software. This system upgrade eliminates the need to replace existing control systems with new generation products.

For more information on MD&As products and services please call (518) 399-3616. Visit us on-line at www.MDAturbines.com

Pre-Outage & Post-Outage Analysis

Plant owners seek to simultaneously improve thermal efficiency, decrease fuel costs and increase power output. Scheduling an overhaul to meet these objectives is an important part of the plant management process. MD&A assists in meeting these goals by analyzing turbine cycle efficiency and making recommendations for correcting thermal problems during your next outage. Our analysis focuses on determining the thermodynamic condition of your steam turbine and the other components in the steam cycle. A preoutage analysis helps to isolate problems and to determine what these problems may be. Heat rate and cycle data collected from station instrumentation is often used to identify performance issues and help managers determine the optimum repairs to be conducted. Solid particle erosion, foreign object damage, deposits, seal rubbing, and other types of damage have distinct thermodynamic signatures that become apparent only with proper data analysis. Monitoring of key pressures, temperatures flows, and output allows owners to choose the right time to perform maintenance or to alter operation and postpone an outage. MD&A provides trending of casing efficiencies, corrected heat rate and power output, key pressure patterns, and other diagnostic information to pinpoint problem areas and to provide a basis for making important maintenance decisions.

Deborah H. Cioffi, P.E., helps turbine owners define thermal performance problems in the steam turbine cycle through testing, data analyses and steampath inspections. Deborah has been improving steam turbine performance for 23 years, has published 12 papers, and received both her Bachelor and Master of Engineering degrees from Rensselaer Polytechnic Institute.

Evaluating & Improving Steam Turbine Performance Seminar

This seminar demonstrates the practical use of thermodynamic, fluid mechanic and design principles as they apply to the troubleshooting, maintenance, and operating needs of power plant engineers. Approximately three sessions are conducted each year. Material follows the chapter sequence of the text of the same title, authored by KC Cotton. The course is highly beneficial to anyone involved in determining, maintaining and maximizing the performance of a steam turbine. It has been designed to present a clear understanding of the many cause-effect performance issues commonly encountered in nuclear, fossil and industrial power plants up to 1100 Megawatts. Strong emphasis is placed on real life, hands-on operation, maintenance, and data analysis situations. Sections are devoted to conducting turbine testing, steampath audits and analyzing data collected from station instrumentation and the DCS. Lessons are intended to provide the take-home knowledge needed to immediately reduce the heat rate of your power plant. This seminar is conducted several times each year. Locations vary. Visit www.MDAturbines.com for currently scheduled classes.
This seminar is considered by many utilities to be required course work for turbine performance engineers. Material teaches techniques to maximize plant output, improve heat rate and increase plant efficiency.

For more information on MD&As products and services please call (518) 399-3616. Visit us on-line at www.MDAturbines.com

One Call One Source Powerful Solutions

CORPORATE OFFICES
518-399-3616
Mechanical Dynamics & Analysis, Ltd. 19 British American Blvd. Latham, NY 12110 Tel: (518) 399-3616 Fax: (518) 399-3929 www.MDAturbines.com