Superior Turbine Solutions, Inc. Steam Path Capabilities Rotor Repair Bucket/Blade Replacement Bucket Cover/Shroud Band Replacement Bucket/Blade Tenon.

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


Rotor 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


Rotor Repair


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


Rotor Repair


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


Rotor Repair

• Bucket/Blade Tenon Weld RepairDuring 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.


Rotor 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


Rotor Repair Cracked Tie Wire


Rotor 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.


Rotor 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.


Rotor Repair

Remove Erosion Shields


Rotor Repair

Clean Blade Platform


Rotor Repair

Silver Solder New Erosion Shield


Rotor Repair

After Final Polishing


Rotor 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


Rotor 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


Rotor Repair

LP Rotor Repair - Removal Of Last Stage Blades


Rotor RepairLP Rotor Repair - View Of Dovetail Before New Blades Are Install


Rotor RepairLP Rotor Repairs – Installing New L-0 Row Of Blades


Rotor Repair

LP Rotor Repairs – Some Blades Require Machining Before Installing Blade Into Wheel


Rotor RepairLP Rotor Repair - Ream L-0 23” Blades


Rotor RepairLP Rotor Repairs - Tenons are peened after the shroud bands have been

fitted.


Rotor Repair

LP Rotor Repairs - LP Rotor Machining


Rotor Repair

• Low Speed Balancing

Low speed balancing can be provide by STS utilizing a Schenck H-90T 100 Ton Portable Balancing Machine.

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


Turbine Parts


Turbine Parts

Superior Turbine Solutions, Inc. Steam Path Capabilities Rotor Repair Bucket/Blade Replacement Bucket Cover/Shroud Band Replacement Bucket/Blade Tenon.

Documents

superior turbine solutions

turbine rotors

tie wire slide

lp rotor

erosion shields slide

replacement seals slide

machining of steam seal

specification slide