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Superior Turbine Solutions, Inc. Steam Path Capabilities Rotor Repair

Superior Turbine Solutions, Inc. Steam Path Capabilities Rotor Repair. Bucket/Blade Replacement Bucket Cover/Shroud Band Replacement Bucket/Blade Tenon Weld Repairs Tie Wire Repairs Lashing Lug Repairs Erosion Shield Replacement Turbine Rotor Machining Low Speed Balancing.

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Superior Turbine Solutions, Inc. Steam Path Capabilities Rotor Repair

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  1. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair • Bucket/Blade Replacement • Bucket Cover/Shroud Band Replacement • Bucket/Blade Tenon Weld Repairs • Tie Wire Repairs • Lashing Lug Repairs • Erosion Shield Replacement • Turbine Rotor Machining • Low Speed Balancing

  2. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair • Bucket/Blade Replacement Replace buckets/blades on turbine rotors. We can: - Remove the old blades from the wheel - Coordinate blast clean and N.D.E. - Install new blades - Layout and punch the new covers - Peen tenons - Finish machine to O.E.M specifications

  3. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair • Bucket Cover/Shroud Band Replacement Two methods to perform this work. First Method : - Remove the old bucket covers/shroud bands - Machine the bucket/blade vane tips to increase the active tenon height - Install new bucket covers/shroud bands - Peen tenons - Finish machine to O.E.M specification

  4. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair • Bucket Cover/Shroud Band Replacement Second Method : - Remove the old bucket covers/shroud bands - Do what is known as a “Fox Hole” cover repair (this is done to increase the active tenon height) - Install new covers/shroud bands - Peen tenons - Machine new bucket covers/shroud bands back to O.E.M specifications

  5. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair • Bucket/Blade Tenon Weld Repair During a forced outage or, regular scheduled outage, a customer may have problems with their seal strips cutting into the blade shroud bands/covers, lifted shroud bands/covers or, simply erosion to the tenons due to poor steam quality. We can perform the following repairs: - We can remove the old shroud bands/covers - Prepare the tenons for welding - Weld tenons using 410SS filler material - Stress relieve tenons - Grind tenons back to original configuration - Make new fox hole shroud bands/covers - Peen and finish machine.

  6. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair • Tie Wire & Tie Wire Hole Repairs Tie wires are used on General Electric style turbines or manufacturers that follow General Electric design. At times when a unit is overhauled , cracks are found in the tie wire or the tie wire hole in the blade. These can be repaired during the overhaul. The normal repairs consist of: - Replacing the tie wire - Installing a sleeve over the crack in the tie wire - Weld repairing the bucket/blade tie wire hole

  7. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor RepairCracked Tie Wire

  8. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair • Lashing Lug Repairs Lashing lugs are normally found on Westinghouse turbines or other manufacturers that follow Westinghouse designs. It’s typical during an overhaul to find cracks in the Lashing Lugs. The Lashing Lugs are what connect individual blades into blade groupings on the last couple of stages on the LP rotor. The crack indications are normally ground out, N.D.E. is done to the Lashing Lug to insure that all of the crack indications have been removed , then the Lashing Lug is re-welded and x-rayed.

  9. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair • Erosion Shield Replacement Erosion shields are normally located on the last couple of stages on the LP rotor. They are a hardened stellite strip that is installed to help protect the leading edge of the blades. After years of operation, missing erosion shields, excessive wear, crack indications, or loose bonds may make it necessary to replace the shields. These can be replaced very easily in the field by : - Removing the old erosion shield - Repairing the blade platform - Fitting a new erosion shield on attaching it using silver soldier - Erosion shield is then ultrasonic tested to insure that they are bonded properly.

  10. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair Remove Erosion Shields

  11. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair Clean Blade Platform

  12. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair Silver Solder New Erosion Shield

  13. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair After Final Polishing

  14. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair • Seal Replacement - Turbine Rotor Replacement of the seals on the turbine rotor is very common during an overhaul, especially on Westinghouse steam turbines. We can: - Remove the old seal - Clean and inspect groove - Install new seal - Finish machine the seal back to original design

  15. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair • Turbine Rotor Machining Various machining operations can be performed to turbine rotors. A few examples would be machining of: - Bearing Journals - Re-Machining of Steam Seal Areas (either high/low teeth or straight shaft seal areas) - Machining of Inner Stage Areas - Machining of Shroud Bands/Covers - Machining of Replacement Seals

  16. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair LP Rotor Repair - Removal Of Last Stage Blades

  17. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair LP Rotor Repair - View Of Dovetail Before New Blades Are Install

  18. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair LP Rotor Repairs – Installing New L-0 Row Of Blades

  19. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair LP Rotor Repairs – Some Blades Require Machining Before Installing Blade Into Wheel

  20. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair LP Rotor Repair - Ream L-0 23” Blades

  21. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair LP Rotor Repairs - Tenons are peened after the shroud bands have been fitted.

  22. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair LP Rotor Repairs - LP Rotor Machining

  23. Superior Turbine Solutions, Inc.Steam Path CapabilitiesRotor Repair • Low Speed Balancing Low speed balancing can be provide by STS utilizing a Schenck H-90T 100 Ton Portable Balancing Machine.

  24. Superior Turbine Solutions, Inc. Quality parts provided by STS include: - Turbine Buckets/Blades - Coupling Bolts - Shroud Bands - Studs - Pins/Reamers - Nuts - Tie Wires - Erosion Shields - Segmented Packing - J Strip Seals - Valve Stems - Valve Seats - Valve Disks

  25. Superior Turbine Solutions, Inc.Steam Path CapabilitiesTurbine Parts

  26. Superior Turbine Solutions, Inc.Steam Path CapabilitiesTurbine Parts

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