MM M05 4

Project Dwg. No: G101-25-1700.
01-MM52
Steam Admission Valves

MECHANICAL MAINTENANCE MANUAL
PT PAITON ENERGY
PAITON EXPANSION PROJECT
Steam Admission Valves Maintenance

Manual No. MM-M05.02
Revision 001
Note
This mechanical maintenance manual is intended to provide the Paiton Expansion Project
mechanical maintenance personnel with the basic understanding required to perform preventive,
routine, corrective and overhaul maintenance activities on the subject equipment.
No part of this document may be reproduced for use by parties other than Mitsubishi Heavy
Industries, Ltd. and Paiton Expansion Project.
Steam
Admission
Valves
Maintenance
Be sure to read this manual.

Contents
Safety
General
Specifications
Preventive Maintenance
Disassembly and Reassembly
Corrective Maintenance
Recommended Lubrication
Appendixes
Contents
Contents
Revision Record i
Important Informationii
Warranty v
Limitation of Liabilityvii
Copyrightix
Personnel to whom the Manual is Directed x
Contact Addressxi
Abbreviations xii
List of Vendor Manuals xiii
Arrangement of the System Maintenance Manualxiv
Chapter1
Safety ____________________________
1.1
Feature of the Steam Admission Valves Safety 1-1
1.2
Warnings Description 1-2

1.2.1
Definitions of Serious Injury, Minor Injury, Serious

Damage to Property, and Minor Damage to Property 1-3
1.2.2
Symbol 1-4
1.2.3
Hazard Warning Label 1-5
1.2.4
Hazard Area 1-7
1.3
Risk Assessment Standard 1-8
1.4
Safety Measures 1-10

1.4.1
Work Permit System (Lockout/Tagout) 1-10
1.4.2
General Cautions on Personnel in Working Area 1-11
1.4.2.1 Caution against Rotating Equipment 1-11

1.4.2.2 Cautions against Electrical Equipment 1-11
1.4.2.3 Cautions against High Temperature Sections 1-12
1.4.2.4 Cautions for Steam Leak in the Plant 1-13
1.4.2.5 Cautions against Oil Leak in the Plant 1-13
1.4.2.6 Cautions against Chemicals 1-14
1.4.2.7 Cautions against Combustible Materials/Storage Areas 1-14
Rev.001
1.4.2.9 Cautions against Lifting Heavy Object 1-16
MM-M05.02
1.4.2.8 Cautions against Lack of Oxygen 1-15
1.4.2.11Cautions using Fork Lift 1-16
1.4.2.10Cautions against Sharp Objects 1-16

Mitsubishi
Contents
Chapter1
Safety (Continued from previous page)

1.4.2.12Cautions using Crane 1-17
1.4.2.13Disposal 1-18
1.5
Emergency Measure 1-19

1.5.1
Evacuation on Emergency Case 1-19
1.5.1.1 Evacuation Route 1-19

1.5.1.2 Evacuation of Disabled Persons who cannot move
by themselves 1-19
1.5.1.3 Evacuation from the Power House 1-20
1.5.2
Fire Accident 1-21
1.5.3
Earthquake 1-22
1.5.4
Explosion Accident 1-22
1.6
Qualification and Training 1-23
Chapter2
General___________________________
2.1
Purpose
2-1
2.2
References
2-1
2.3
Overview of Turbine Steam Admission Valves
2-3
2.4
Construction and Arrangement
2-8
2.4.1
HP Turbine Steam Chest and Steam Admission

Valves
2-8
2.4.2
IP Turbine Steam Admission Valve Assemblies
2-31
2.4.3
Steam Admission Valve Control Oil System
2-48
Chapter3
Specifications _____________________
Chapter4
Preventive Maintenance _____________
4.1
Prerequisites 4-1
Scheduling
4-1
4.1.2
Department Interface/Notification
4-2
4.1.3
Isolation of Equipment
4-2
4.1.4
Safety Precautions
4-2
MM-M05.02
Rev.001
4.1.1

Mitsubishi
Contents
Chapter4
4.2
4.3
Chapter5
Preventive Maintenance (continued) ______

Routine Maintenance
4-3
4.2.1
Preparation
4-3
4.2.2
Inspection and Maintenance
4-3
Annual Outage Maintenance
4-4
4.3.1
Preparation
4-4
4.3.2
Inspection and Maintenance
4-5
Disassembly and Reassembly ________
5.1
Disassembly and Reassembly of Main Stop Valve
5-1
5.2
Disassembly and Reassembly of Governing Valve
5-14
5.3
Disassembly and Reassembly of Reheat Stop Valve
5-24
5.4
Disassembly and Reassembly of Interceptor Valve
5-35
5.5
Disassembly and Reassembly of Steam Admission

Valve Actuators
5-44
Chapter6
Corrective Maintenance _____________
6.1
Prerequisites
6-1
6.2
Preparation
6-2
6.3
Troubleshooting
6-2
Chapter7
Recommended Lubrication __________
Appendix A
Torque Chart A-1
Appendix B
Recommended Spare Parts B-1
Appendix C
Special Tools C-1
Appendix D
Coupling Alignment D-1
Appendix E
Applicable Reference Drawings E-1
Appendix F
Controlled Tightening ProceduresF-1
Appendix G
Valve Parts Removal Procedure Drawings G-1
Appendix H
Ultrasonic Cleaning H-1
MM-M05.02
Rev.001
Appendixes

Mitsubishi
Contents
MM-M05.02
Rev.001
List of Figures
1-1
Types of Hazard Warning Label
1-6
1-2
Mapping of Hazard Areas
1-9
2-1
Isometric View of the Turbine and Steam

Admission Valves
2-5
2-2
HP Turbine Steam Admission Valves Assembly
2-6
2-3
IP Turbine Steam Admission Valves Assembly
2-7
2-4
Cutaway View of Steam Chest and HP Turbine

2-21
2-5
Arrangement of Steam Chest Support
2-22
2-6
Sectional View of Main Stop Valve
2-23
2-7
Schematic Arrangement of Main Stop Valve

Actuator and Servo-system
2-24
2-8
MSV Actuator Assembly
2-25
2-9
Sectional View of Governing Valve
2-26
2-10
Schematic Arrangement of Governing Valve

2-27
2-11
GV Actuator Assembly
2-28
2-11a
MSV Pilot Valve Characteristic Curve 2-29
2-11b
GV Characteristic Curve 2-30
2-12
Cutaway View of the RSV-ICV Assembly
2-39
2-13
Support Arrangement for the RSV / ICV Assembly
2-40
2-14
Sectional View of Reheat Stop Valve
2-41
2-15
Schematic Arrangement of Reheat Stop Valve

2-42
2-16
RSV Actuator Assembly
2-43
2-17
Sectional View of Interceptor Valve
2-44
2-18
Schematic Arrangement of Interceptor Valve

Actuator and Servo-System
2-45
2-19
ICV Actuator Assembly
2-46
2-19a
ICV Characteristic Curve 2-47
2-20
Control Oil Flow Diagram for Steam

Admission Valves (1 of 2)
2-21

Mitsubishi
2-49
Control Oil Flow Diagram for Steam

Admission Valves (2 of 2) 2-50
Contents
List of Figures
4-1
Main Stop Valve NDT Areas
4-11
4-2
Governing Valve NDT Areas
4-12
4-3
Reheat Stop Valve NDT Areas
4-13
4-4
Interceptor Valve NDT Areas
4-14
4-5
NDT on Cover Joint Nuts & Spherical Washers
4-15
4-6
Main Stop Valve Clearance Drawing
4-16
4-7
Governing Valve Clearance Drawing
4-17
4-8
Reheat Stop Valve Clearance Drawing
4-18
4-9
Interceptor Valve Clearance Drawing
4-19
5-1
Exploded View of Main Stop Valve
5-12
5-2
Removal Procedure for MSV Spring Guide Stem
5-13
5-3
Exploded View of Governing Valve
5-23
5-4
Exploded View of Reheat Stop Valve
5-34
5-5
Exploded View of Interceptor Valve
5-43
5-6
General Disassembly Sequence for a Steam

Admission Valve Actuator
5-48
Disassembly Sequence for a Steam Admission

Valve Actuator Hydraulic Cylinder
5-49
C-1
Special Tools List C-2
E-1
Main Stop Valve Assembly (1 of 3)
E-2
E-2
E-3
E-3
E-4
E-4
Governing Valve Assembly (1 of 3)
E-5
E-5
E-6
E-6
E-7
E-7
Reheat Stop Valve Assembly (1 of 3)
E-8
E-8
E-9
E-9
E-10
E-10
Interceptor Valve Assembly (1 of 2)
E-11
MM-M05.02
Rev.001
5-7

Mitsubishi
Contents
List of Figures (continued from previous page)

Interceptor Valve Assembly (2 of 2)
E-12
E-12
MSV Actuator Assembly (1 of 2)
E-13
E-13
MSV Actuator Assembly (2 of 2)
E-14
E-14
GV Actuator Assembly (1 of 2)
E-15
E-15
GV Actuator Assembly (2 of 2)
E-16
E-16
RSV Actuator Assembly (1 of 2)
E-17
E-17
RSV Actuator Assembly (2 of 2)
E-18
E-18
ICV Actuator Assembly (1 of 2)
E-19
E-19
ICV Actuator Assembly (2 of 2)
E-20
G-1
Removal of MSV Actuator
G-2
G-2
Removal of MSV Spring Housing
G-3
G-3
Removal of MSV Bonnet
G-4
G-4
Removal of GV Actuator
G-5
G-5
Removal of GV Spring Housing
G-6
G-6
Removal of GV Bonnet
G-7
G-7
Removal of RSV Cover and Trip Pilot Valve
G-8
G-8
Removal of RSV Actuator
G-9
G-9
Removal of ICV Actuator
G-10
G-10
Removal of ICV Spring Housing
G-11
G-11
Removal of ICV Bonnet
G-12
MM-M05.02
Rev.001
E-11

Mitsubishi
Contents
List of Tables
Risk Assessment Standard
1-8
3-1
Turbine Steam Admission Valves
3-1
4-1
Outage Maintenance Checklist
4-6
6-1
Troubleshooting Steam Admission Valves and

Actuators
6-3
A-1
Torque Chart
A-1
A-2
Controlled Tightening
A-2
B-1
Spare Parts List
B-1
F-1
Stretch Alloys for Alloy Steel Bolts or Studs
F-1
F-2
Nominal Diameter of Bolts Versus Tightening Torque
F-2
MM-M05.02
Rev.001
1-1

Mitsubishi
Revision Record
Page Number
General
Description of Revision
Revision record added. All
Revision Issue
Date
Date Revised
Pages
Inserted
2012/04/10
2012/04/10
2012/04/10
2012/04/10
2012/04/10
pages modified to revision

001.
Page 2-4
Top para. modified in Chapter

2 Section 2-3.
Page 2-29
Chapter 2 Figures 2-11a
2-30
2-11b added.
Page 2-47
Chapter 2 Figures 2-19a
and
added.
Page C-2
Appendix C Figure C-1
MM-M05.02
Rev.001
Special Tools List Added.

Mitsubishi
Important Information
Purpose of the Plant Usage
This plant is designed to generate electric power of 815 MW by the steam turbine
generator.
The plant is only used for the electric power generation purpose that supports stable
and reliable electric power supply to the power grid and supplying steam for auxiliary
equipment in the power station.
General
1.
To satisfy the purpose mentioned above the following points must be strictly
observed,
a)
The operation, maintenance and inspection of Equipment must be

performed by the persons who have basic technical knowledge and have
been trained concerning the hazard of the Equipment and the avoidance
of the hazard.
b)
The operators and maintainers must read and understand these manuals
before starting the operation, maintenance or inspection.
It is often experienced that serious damage to the equipment or personnel
have occurred by the unexpected action of operators or maintainers who
do not fully understand the equipment.
c)
The modification or change of operational specification must be performed

under MHI supervision or as per the written acceptances of MHI.
The modification or change of specification causes not only a decline in
performance but also a decline in safety for operation of the equipment.
The Customer is requested to contact MHI regarding any modification or
proposed changes before the work commences.
MM-M05.02
Rev.001
The address for MHI to be contacted is shown in this chapter.

2.
The operation and maintenance must be performed according to the applicable

laws and regulations at the location of the power station.
3.
Disposal from the power station must be treated to satisfy the local regulations.
4.
The copyright of software, drawings and other documents provided by MHI at

all times, is still reserved by MHI.

Mitsubishi
ii
Use or copying of the whole or part of any information provided by MHI for
any purpose other than operation and maintenance of this plant without
written consent is strictly prohibited.
Important General Notice for Safety

1.
The operator and maintainer must have knowledge about the equipment to
maintain good operating condition and to avoid danger when using the
equipment and systems.
2.
The protection measures must satisfy all of the operational functions.
3.
The safety activity must be planned systematically as a Safety and Health

management system and operate continuously.
Safety and Health management system must include the following points,
a) Instruction for use and the maintenance of the personal protective
equipment supplied to operators and maintainers
b) The establishment of a work management organization to make clear the
operation directives and work procedures
c) Implementation of training for operator and maintainer
4.
The Customer must train the operators and maintainers to act positively and
to prevent the occurrence of an accident by using their knowledge of the
power plant.
5.
The Customer must make the operators and maintainers understand that the
most important purpose of safety control is to protect all personnel from
accidents and also to maintain operation of the plant without troubles.
6.
To prevent accidents involving personnel and equipment, it is necessary to

observe the notices of this manual and to keep the correct operation
according to the description provided in this manual.
If the notices are not observed, the following dangers could occur to the
operator and to the maintainer.
MM-M05.02
Rev.001
7.
a)
Risk of a fatal accident
b)
Danger to lose his health and fitness
c)
Danger of damage to the equipment
MHI can not forecast all possible dangers existing in the plant such as danger
due to human error and/or dangers caused by the operating environment.
As this manual and the alert label cannot cover all of the dangers, the
operators and maintainers have to pay their full attention to all general safety
notices.

Mitsubishi
iii
8.
MHI can not be responsible for damages and injury caused by neglecting the
notices in this manual, and other necessary general notices.
Instruction of this Manual

This manual is provided for people familiar with the use of English. If some
person not familiar with English is going to operate the plant, the Customer
must train him specially.
2.
The warning labels are to be expressed in the English language.
3.
This manual contains optional matters.
4.
Some figures in this manual include internal parts of the equipment which
may not be obvious, when looking at the completed equipment drawing.
5.
MHI may change the content of this manual without notice.
6.
This manual is intended for the use by the operators and maintainers and it
must be accessible to them at all times.
7.
If the Customer needs more detailed information, please contact MHI local
office or MHIs official agent.
MM-M05.02
Rev.001
1.

Mitsubishi
iv
Warranty
The provisions set forth in this section are in addition to all liability and warranty
disclaimers and limitations set forth in the Contract, whether arising under law
or from course of performance, course of dealing, or usage of trade.
Nothing in these provisions shall constitute or be deemed to constitute any

additional liability undertaking or warranty, express or implied, with respect to
the Plant. All capitalized terms used, but not defined in this Warranty
Limitations section shall have the respective meanings ascribed to them in the
Contract.
The Contract Warranties are subject to the construction, installation and

Commissioning works having been performed in full compliance with the
requirements stated in (a) the Contract, (b) all manuals provided by MHI,
including this manual, (c) all applicable rules, regulations and laws prevailing in
the location where the Plant has been installed and will operate, and (d) any
other instructions, if any, provided by MHI (collectively, Rules and
Requirements). The Contract Warranties will NOT cover any accidents, partial
or total failure of the Plant, losses or damages to personnel or property
(including, without limitation, the Plants components, parts, systems and other
equipment), or any other liability (collectively, Accidents and Damages) in the
case of any breach of the stated Rules and Requirements.
For the detailed terms and conditions of the warranty concerning the Works
and Project, refer to the Contract.
In addition to the foregoing, the Contract Warranties will NOT cover any of the
following Accidents and Damages:
Accidents and Damages caused by any deviation from the Rules and
Requirements;
MM-M05.02
Rev.001

Mitsubishi
Accidents and Damages caused by the modification or re-installation of the

Plant after the original installation, or caused by operation of the Plant for a
purpose other than that for which it is designed;
Accidents and Damages caused by natural disasters or accidents during

transfer or related handling;
Accidents and Damages occurring after the term of the warranty has expired;
Accidents and Damages due to faulty operation or operation not in accordance

with the Rules and Requirements;
Accidents and Damages due to inappropriate maintenance or servicing

performed by the Customer, its personnel or any other party.
Accidents and Damages caused by any components, parts, systems or other

equipment other than those delivered by MHI;
Accidents and Damages caused by unidentifiable reasons including loss of the

damaged parts which is necessary to pinpoint a cause of the failure;
Accidents and Damages caused by referring to inadequate, or incorrect

references, data or information provided by the Customer;
Accidents and Damages or rust/corrosion due to inadequate handling and/or

storage by the Customer; or
Accidents and Damages due to handling, storage and/ or use of the Plant
under severe conditions or in an environment that does not meet the design
specification conditions.
MM-M05.02
Rev.001

Mitsubishi
vi
Limitation of Liability
General
Nothing in this Limitation of Liability section or manual shall constitute or be

deemed to constitute any additional liability undertaking or warranty, express
or implied, with respect to the Plant. All capitalized terms used, but not defined
in this Limitation of Liability section shall have the respective meanings
ascribed to them in the Contract.
The contents of this manual are subject to change without prior notice and
without any obligation or liability to MHI.
Use and Disposal
Use of the Plant must be limited to the use specified by MHI, including without
limitation, use of the Plant in accordance with the Contract, this manual, all
Safety Manuals, all applicable laws and regulations, and any other instructions,
if any, provided by MHI. The Plant components, parts, systems and other
equipment (collectively, Equipment) must be appropriately disposed of in
accordance with the Contract, this manual, all Safety Manuals, all applicable
laws and regulations, and any other instructions, if any, provided by MHI.
For Documents and Safety Training
MM-M05.02
Rev.001
The Customers personnel must read, understand and abide by all documents
provided by MHI, including without limitation, the operation and maintenance
manuals, safety manuals, and instruction manuals (collectively, Safety
Manuals) and must have received all required and/or necessary safety
training prior to the start of their work. Persons who have not received such
safety training are not permitted to work on the installed Plant. This initial
training, however, is merely the minimum requirements prior to allowing any
personnel to work on the installed Plant. The Customer must, on a continual
and regular schedule, give up-to-date training to its personnel on safety
requirements, provide testing or other methods to confirm their understanding
of the safety training, and confirm that they have the physical and mental
capability to perform their respective roles. The Customers obligation for
safety training and personnel supervision is an ongoing obligation and must be
continuously performed and kept current throughout the operation of the Plant.
Accidents, partial or total failure of the Plant, damage to personnel or property,
loss, injuries, and other liability (collectively, Liability) caused by inadequate
safety training or the Customers personnels failure to abide by the documents
provided by MHI are expressly excluded from the coverage of any warranty
provided by MHI and are the sole and exclusive responsibility of the Customer.

Mitsubishi
vii
MHI will NOT be liable for any Liability caused by modification or changes
made in Plant-related documents (including any Safety Manual) by anyone
other than MHI.
For Damage to the Plant

Accidents may occur by use of Equipment that is acquired from anyone other
than MHI or anyone not appointed by MHI to modify or repair this Plant. The
Customer shall not be permitted to modify or repair the Plant or change
Equipment of the Plant without MHIs prior written approval, under any
circumstance.
MHI will NOT be liable for any Liability resulting from any abuse, misuse,
misapplication of the Equipment supplied by MHI.
MHI will NOT be liable for any Liability caused by an act by the Customer in
violation of the Contract, this manual, any applicable law or regulation, or any
Safety Manual or any other instruction provided by MHI, including without
limitation, a change of the installation environment or the removal and
installation of any Equipment in a location different to that originally selected by
MHI.
MHI will NOT be liable for any Liability caused by a defect, imperfection, or fault,
in material or Equipment that was used during a repair, even when such repair
was performed by or under an instruction given by MHI.
MM-M05.02
Rev.001

Mitsubishi
viii
Copyright
COPYRIGHT 2008, MITSUBISHI HEAVY INDUSTRIES, LTD. ALL RIGHTS
RESERVED. ANY REPRODUCTION IS EXPRESSLY PROHIBITED.
All of the content contained in this manual is protected by Japanese,
International and/or United States copyright laws.
All copyright, trade secrets, and other proprietary and intellectual property
rights in the documents provided by Mitsubishi Heavy Industries, Ltd.(MHI)
(including safety-and-instruction manuals) are at all times owned and reserved
by MHI. Subject to your compliance with the restrictions set forth below, MHI
grants to you a limited, non-exclusive license in the copyright for the sole
purpose of allowing you to use, operate, maintain and inspect the Plant.
Use, copying, other reproduction of the whole or part of the documents

provided by MHI (including safety-and-instruction manuals) for any purpose
other than the purpose described above without MHIs prior written consent is
strictly prohibited.
The act of rewriting, translating, modifying, revising, creating electronic copies,

uploading, selling, sublicensing, or otherwise disclosing the whole or part of the
manuals is strictly prohibited.
Except as specifically set forth above, no right, title or license to the documents
provided by MHI, whether arising from contract, implication, estoppel or
otherwise, is being granted or otherwise transferred.
MM-M05.02
Rev.001

Mitsubishi
ix
Personnel to whom the

Manual is Directed
This Manual was prepared for all personnel who will participate in the operation and
maintenance of the plant, and the other related mechanical plant and equipment
installed.
In this Manual, MHI classifies personnel into the following two classes based on
their ability, experience and their attitude to the safety of personnel, and the plant
installed.
Only the personnel recognized by the Customer as trained personnel are allowed to
perform the operation and maintenance specified in the manuals.
Maintainers and Operators are required to have read and understood the contents
of the safety, operation, and maintenance manuals and sufficiently understand the
work procedures before actually starting their tasks.
Operator
Operators following the instructions of their supervisor or the Shift Charge Engineer
are permitted to handle materials to be used in the operation of the plant.
Operators are allowed to turn on the power supply, startup equipment, open up or
remove covers or panels on receipt of an instruction or authorization from their
superior.
Operators are permitted access to emergency stop devices following instructions
given by their superior when dangerous or hazardous situations are recognized.
MM-M05.02
Rev.001
Maintainer
Maintainers are permitted to perform maintenance on the plant. They will also
perform troubleshooting routine and periodical inspections of the installed
equipment. The maintainer will also work under the supervision of MHIs
supervisors during on-the-job training and annual maintenance and overhaul work if
MHIs supervisors are requested to witness periodical inspections, etc.
Maintainers MUST have attended the training programme initially provided by MHI
and subsequently by the Customer, and they must have obtained the necessary
knowledge and maintenance skills to understand the characteristics of their tasks
before actually starting their work.
Mitsubishi
Contact Address
For any question or any clarification required, please do not hesitate to contact MHI
through the following address (es).
For Support before Operation:

MITSUBISHI HEAVY INDUSTRIES, Ltd.
Nagasaki Shipyard & Machinery Works
MM-M05.02
Rev.001
1-1, Akunoura Machi, Nagasaki 850-91

Mitsubishi
xi
Abbreviations
Abb.
CCR
C&I
Expanded Form
Central Control Room
Control and Instrumentation
Abb.
Expanded Form
LP
Low Pressure
LVDT
Linear Variable Differential

Transformer
Digital Electro-hydraulic
MSDS
Material Safety Data Sheet
DTI
Dial Test Indicator
MSV
Main Stop Valve
E/H
Electro-hydraulic
NDE
Non-destructive Examination
Gen
Generator
OD
Outside Diameter
Gov
Governor
OJT
On Job Training
GV
Governing Valve
OPC
Overspeed Protection Control
HP
High Pressure
P&ID
Process and Instrumentation

Diagram
ICV
Interceptor Valve
PPE
Personal Protective Equipment
ID
Inside Diameter
PTW
Permit to Work
IP
Intermediate Pressure
RSV
Reheat Stop Valve
MM-M05.02
Rev.001
DEH

Mitsubishi
xii
List of Vendor Manuals
MM-M05.02
Rev.001
NIL

Mitsubishi
xiii
Arrangement of the System

Maintenance Manual
This manual is arranged as follows.
Chapter 1
Describes health and safety issues during maintenance, disassembly and reassembly
of the Steam Admission Valves.
Chapter 2
Describes the construction, purpose, and function of the Steam Admission Valves.
Chapter 3
Describes the Steam Admission Valves, using the relevant Data Sheets.
Chapter 4
Describes the Preventive, Routine, and Outage Maintenance.
Chapter 5
Describes the disassembly and reassembly procedures, necessary to obtain access
to internal parts for inspection and repair during overhaul of the Steam Admission
Valves.
Chapter 6
Describes the corrective maintenance procedures to be followed to investigate,
identify and remedy defects occurring during operation.
MM-M05.02
Rev.001
Chapter 7
Includes Torque Chart, Spare Parts, Special Tools and Vendor Drawings/Documents

Mitsubishi
xiv
Chapter 1
Safety
C h a p t er
1 S af et y
1.1
Feature of Steam Admission Valves Safety

The main turbine is the equipment that rotates at high speeds using high pressure
and high temperature steam from the boiler. The steam admission valves supply
and control the main and reheat steam required to drive the main turbine.
The steam turbine is subject to sudden pressure and flow variations due to
fluctuation in generator load or due to disturbance in boiler firing. The steam
admission valves adjust automatically to these flow variations. The steam
admission valves are operated by high pressure oil system to have an efficient and
fast response for the sudden changes in the operating requirement of the steam
turbine.
The oil flow and hence pressure variations caused during the steam admission
valves operation are relieved by relief valves installed on the lubricating oil and
control oil piping. However, due to the sudden oil pressure fluctuation and ageing of
flange gaskets, the oil piping continues to have a high risk of flange/pipe leakage.
Leaked oil from the oil piping can cause extensive damages in the vicinity of the
turbine in the event of a fire. All personnel, operators or maintainers, during their
frequent patrols around the Steam Turbine are aware of the danger, and must
report any changes to the Shift Charge Engineer, who will take on the responsibility
regarding any urgent immediate action.
The steam admission valves are susceptible for steam leakages due to gasket
failure or due to the mal-operation of the gland steam condenser. This may result in
steam leakage within the turbine enclosure and is a cause of concern as it may lead
to fire if allowed to continue for a long time. All operators and maintainers should
pay special attention if any hissing steam flow noise is observed near the steam
admission valves to reduce consequential damages should any steam leakage
occur.
MM-M05.02
Rev.001
All operators and maintainers must realize the danger and keep themselves safe,
following the recommendation written in this chapter.

Mitsubishi
1-1
Chapter 1
1.2
Safety
Warnings Description
Safety of personnel working in the power plant is the most important matter and all
kind of consideration to avoid dangerous condition are studied and applied to the
design of the power plant. However, certain risks are unavoidable due to the nature
of the plant.
This manual classifies the severity and hazard level of such risks by two categories,
DANGER and CAUTIONS. Read and understand the indications thoroughly
before operation or maintenance of the plant.
The contents of wordings, DANGER and CAUTION are described as follows;
Kinds
Meaning of Warnings
DANGER indicates an imminently hazardous situation
during use of the Steam Admission Valves, which, if not
avoided, could result in death or serious injury, or
serious damage to the property or environment.
CAUTION indicates a potentially hazardous situation
CAUTION
during use of the Steam Admission Valves, which, if not

avoided, may result in minor injury or minor damage to
the property or environment.
This manual also uses the following indicators in addition to the hazard level
indications described so far.
Kinds
Meaning of Warnings
IMPORTANT describes the particular information or
items that personnel must know during operation and
IMPORTANT
maintenance of the Steam Admission Valves, and that, if

not heeded, may result in an accident of an
in-assessable hazard level.
NOTICE describes useful information and tips for
Notice
operation and maintenance of the Steam Admission
MM-M05.02
Rev.001
Valves.

Mitsubishi
1-2
Chapter 1
Safety
1.2.1 Definitions of Serious Injury, Minor Injury, Serious

Damage to Property, and Minor Damage to Property
Serious Injury
This term describes injuries, which leave after effects such as loss of eye
sight, permanent disability, bone fracture or breakage, gas inhalation,
asphyxiation, electric shock, hospitalization or prolonged hospital visits for
treatment.
Minor Injury
This term describes injuries, which do not require hospitalization or
prolonged attention at a hospital (injuries other than the serious injuries
described above).
Serious Damage to Property

This term describes damages, which require a suspension of productive
activity for one day or more due to restoration of the damaged property.
Minor Damage to Property
MM-M05.02
Rev.001
This term describes damage, which does not require any suspension of
productive activity due to restoration of the damaged property.

Mitsubishi
1-3
Chapter 1
Safety
1.2.2 Symbol
In this manual, the following symbols are added for easy understanding of
the contents of warnings and are found next to DANGER, CAUTION
and indications.
These symbols are in compliance with ISO 3684.
Symbol
Description
This symbol indicates the possible presence of high voltage, and
warns of a hazard which may result in system shock, burn or
death by electric shock if safety precautions are neglected or the
system is handled incorrectly.
This symbol indicates a movable section that is inside a safety
cover or is exposed.
Movable parts may inflict laceration or bone fracture to body parts
such as a hand by pinching the hand and/or clothing.
This symbol indicates the presence of parts the surface of which
could be hot, and may cause a burn if handled incorrectly.
This symbol indicates that care should be taken where you place
your feet when moving around the area.
Risk of injury by tripping is present near this symbol due to
factors such as a location with an unstable surface, or
obstructions such as scaffolding, temporary pipe lines, or other
protrusions.
This symbol indicates the possible presence of gas(es) harmful or
asphyxiant to personnel.
Be sure to ventilate fully before work commences.
This symbol indicates caution against the handling of a heavy
object or working in an abnormal position.
Do not work in an abnormal posture which may damage your back
or waist.
This symbol indicates prohibited items or actions during the
MM-M05.02
Rev.001
operation and maintenance of the Steam Admission Valves.

Mitsubishi
1-4
Chapter 1
1.2.2
Safety
Symbols (Continued from previous page)
Symbol
Description
This symbol indicates that personnel must not touch since the
surface is hot.
Do NOT enter any area where this symbol is displayed.
This symbol indicates that the entry of personnel is prohibited.
Do NOT enter any area where this symbol is displayed.
This symbol indicates that physical contact is prohibited.

Do NOT touch or enter a location or enclosure where this symbol
is displayed.
This symbol indicates that the stated items or actions in the
warning notices relative to operation and maintenance of the
Steam Admission Valves are mandatory.
This symbol indicates a movable section that is inside a safety
cover or exposed.
Do NOT touch any equipment where this symbol is displayed.
1.2.3 Hazard Warning Label

Hazard warning labels are applied where potential hazards are present
during operation and maintenance activities.
Hazard warning labels will be in appropriate sizes and colors that will catch
the eye and the attention of personnel. They also have symbols that show
the hazard types, in addition to the descriptions of warning contents.
IMPORTANT
Personnel are requested to confirm the location of, and to read, and
thoroughly understand the contents of all hazard warning labels
applied to this Steam Admission Valves. If any of the hazard warning
labels peel off/wear out or become unreadable, install a new label in
MM-M05.02
Rev.001
the original location without delay.

Mitsubishi
1-5
Chapter 1
WARNING
Safety
DO NOT COME
NEAR TO SHAFT
EXPOSED ZONE
WHEN IN
OPERATION
PINCH POINT
STEEP
DROP
DO NOT
ENTER
DO NOT
TOUCH
DO NOT
TOUCH
MM-M05.02
Rev.001
TB0001_A
FIGURE
Mitsubishi
1-1
TYPES OF HAZARD WARNING LABEL
1-6
Chapter 1
Safety
1.2.4 Hazard Area
IMPORTANT
MM-M05.02
Rev.001
Only trained maintainers and operators are allowed to enter the

maintenance work area. Entry to the area by personnel untrained
could cause not only injury but also serious damage to the Steam
Admission Valves.

Mitsubishi
1-7
Chapter 1
1.3
Safety
Risk Assessment Standard

As prepared by the Design Section as per MIL STD822D.
TABLE 1-1
RISK ASSESSMENT STANDARD

Detailed Description of Impact on each Object
Category
Safety
Catastrophic
- Unit shutdown (unit cannot be

operated)
- More than 4 days for repairing
II
Critical
- Unit shutdown (can not be operated)

- Within 3 days for repairing
III
Marginal
- Unit shutdown (can not be operated)

- Can be repaired by Customer
VI
Negligible
TABLE 1-1
Environment
- Death
- Harmful liquid (such as

Oil) running out of the
plant
- Serious Injury
- Not harmful liquid

running out of the plant
- Minor Injury
(with
hospitalization)
- Minor Injury
(without
hospitalization)
- Harmful liquid (such as

Oil) leaking in the plant
- Not harmful liquid
leaking in the plant
RISK ASSESSMENT STANDARD (CONTINUED)
Definition
Description
Category
Detailed
(A)
Frequent
Repeating occurrence
1 time / 1 or 2 months
(B)
Probable
Known to occur, or, it has happened
1 time / 1 year
(C)
Occasional
Could occur
1 time / 5 years
(D)
Remote
Not likely to occur
1 time / 10 years
(E)
Improbable
Practically Impossible
1 or 2 times / total life
TABLE 1-1
Hazard
Categories
Frequency
of Occurrence
RISK ASSESSMENT STANDARD (CONTINUED)

I
II
III
VI
Catastrophic
Critical
Marginal
Negligible
(A)
Frequent
13
(B)
Probable
16
(C)
Occasional
11
18
(D)
Remote
10
14
19
(E)
Improbable
12
15
17
20
MM-M05.02
Rev.001
Health

Mitsubishi
1-8
Chapter 1
10
5
3
2
10
5
3
2
10
5
3
2
10
5
3
2
7
4
3
4
3 9
2 8
1 7
7
4
3
Safety
7
4
3
7
4
3
4
3
STAIR WAY
2
3
5
10
3
7
8
3
4
7
STAIR WAY
2
3
5
10
2
3
5
10
2
3
5
10
3
4
7
3
4
7
1 7
2 8
3 9
4
3
4
7
NOTES
WARNING LABELS SHOUD BE IN ARABIC.
GEN. SIDE
MM-M05.02
Rev.001
YELLOW
AVOID INJURY
WATCH YOUR STEP
YELLOW
FALL
WATCH YOUR STEP
MPTD-3-0314
YELLOW
RISK OF A ROTATING
A HAND
YELLOW
RISK OF A GEAR
PINCHING A HAND
GOV. SIDE
(*1)
YELLOW
RISK OF A CHAIN
PINCHING A HAND
YELLOW
PINCH POINT
KEEP HANDS AWAY
YELLOW
YELLOW
DO NOT TOUCH
HOT SURFACE
YELLOW
YELLOW
DISCONNECT
AUTOMATIC START.
ELECTRICAL POWER
KEEP HANDS CLEAR.
BEFORE SERVICING
RED
DO NOT SMOKE
IN THIS AREA.
10
RED
OPERATING PERIOD
(*1) THE MOST SUITABLE ONE WILL BE ADOPTED TO EACH PLACE.
FIGURE 1-2
Mitsubishi
YELLOW
MAPPING FOR HAZARDOUS AREA
1-9
Chapter 1
1.4
Safety
Safety Measures
1.4.1 Work Permit System (Lockout/Tagout)
Work permit system is applied when equipment is shutdown for
maintenance work, to complete the maintenance work under a safe
condition. The outline of the work permit system is as follows:
(1)
The Maintenance Engineer applies for the work permit clearly

indicating the content of the maintenance work that he wants to do,
and submits it to the Shift Charge Engineer.
(2)
The Shift Charge Engineer passes the work permit form to the
operator to study and decide the isolation method from the line in
operation on the mechanical and electrical view point and then report
to the Shift Charge Engineer with the comments on the hazard
conditions for the work.
(3)
The Shift Charge Engineer gives work permit number and prepares
necessary tags to show the work permit number and the situation of
isolation by valves and power supply. He will then instruct the
operators to set the isolation condition following the work permit
form.
(4)
The operators will open the breaker and set the valves to the
specified condition. They will also drain and vent the equipment to be
worked on and the breaker and the valves are to be locked. The
operators return the work permit to the Shift Charge Engineer.
(5)
The Shift Charge Engineer confirms the isolation and will issue the
signed work permit to the Maintenance Engineer, or his
representative.
(6)
The Maintenance Engineer orders the start of the maintenance work

to the workers nominated.
(7)
The Maintenance Engineer or his representative will then return the

signed off work permit to the Shift Charge Engineer after confirming
the maintenance work is completed.
(8)
The Shift Charge Engineer will then send operators to release the
locks and return to the original situation.
(9)
The operators confirm the situation and report that the system is now
back to the normal condition when signing off the work permit.
The work permit system is to clarify responsibility for the works on each
step and to ensure that the work is performed safely.
MM-M05.02
Rev.001
(10) The Shift Charge Engineer confirms that the work under the permit is
completed and files details in the log book.

Mitsubishi
1-10
Chapter 1
Safety
1.4.2 General Cautions on Personnel in Working Area

1.4.2.1
Cautions against Rotating Equipment

All couplings on rotating machines are covered by the
coupling cover but whole parts of the shaft are not fully
covered. It is recommended that the following warning is
observed strictly.
Do not approach or operate the equipment where

protective covers have been removed. Get additional
supervisor assistance.
Make sure that the breaker for the motor is opened when
you are required to remove the cover.
Care must be taken of the exposed rotating parts,

especially in the area between the casing and the coupling.
All shafting, coupling and other rotating parts must be

guarded in order to prevent accidental contact.
1.4.2.2
Cautions against Electrical Equipment
Always, confirm that power supply is disconnected at the

up-stream side of power supply system and it is locked
according to the Work Permit.
Do not remove or open panels or doors labeled with high

voltage live part warning label not included in the Work
Permit.
Ensure the proper earthing is provided for all electrically

operated tools and equipment used for maintenance works.
Rev.001
In case of usage of lamps for internal inspection, ensure

that a low voltage system (24volts) is available.
MM-M05.02
The electrical equipment covered under this section includes

all the concerned plant equipment and the maintenance tools
like grinders, lamps, welding equipment etc. Though live parts
of the plant or maintenance tools are insulated, be sure to
observe the following cautions. Failure to observe them may
cause fatal accidents, personal injuries and damage to the
electrical equipment.
Make sure that no materials or Parts remain in the Panels or

terminal box before closing them finally.

Mitsubishi
1-11
Chapter 1
1.4.2.3
Safety
Cautions against High Temperature Sections

Various equipment and pipelines contain high temperature fluid
and they are insulated on their surface. There are however some
pipe lines which are not insulated, and as their temperature is
very high and you could get burned, please observe the following
caution to avoid burn injury.
CAUTION
Suitable Personal Protective clothing is always available
and should always be worn, including gloves to avoid
direct contact to hot spots in the plant
Level gauges of pressure vessels including connecting

pipes are not insulated to cool down the steam to drain.
Sampling piping is not insulated to cool down the steam to

suitable temperature for the analyzer except at the places
located close to the work place.
All exhaust pipes of safety valves and the exhaust pipe of

boiler flush pipe are not insulated.
Always wear gloves.
MM-M05.02
Rev.001

Mitsubishi
1-12
Chapter 1
1.4.2.4
Safety
Cautions for Steam Leak in the Plant

The steam leak especially from high temperature steam may
cause serious injury to the personnel and it must be repaired
at an early stage of the leakage. The following pre-cautions
must be followed to find leakage at an early stage.
Water drips may occur at the insulated parts such as the

connected part of the lagging. The leaking point can be found
by removing insulation partially using great care.
As you approach the leakage the water will change to visible

steam. It is now too dangerous to remove the insulation.
Leakage of the superheated steam only makes whistling

noise without generating white steam. It is very dangerous to
approach the noise area.
Contact the Charge Engineer to obtain a Permit to Work to

ensure plant isolation before repairing the damage.
Be well aware of the steam. The steam could leak from the
water system containing water at 100C or higher even if it is
a low pressure type water system.
High temperature drain or steam could leak from the flush

pipe during start-up.
If not avoided, the steam or vapor can enter the inside of your
working wear through the small gap between the body and
the clothing.
1.4.2.5 Caution against Oil Leak in the Plant
MM-M05.02
Rev.001
CAUTION

Mitsubishi
Oil leakage is very dangerous. It is a potential fire hazard.
Any oil spillage must be reported to the Shift Charge

Engineer.
Oil leaks make the area slippery and people are advised to
move around these areas carefully.
1-13
Chapter 1
1.4.2.6
Safety
Cautions against Chemicals

Pay attention to the items listed below to prevent any accident
related to the chemicals in the plant.
IMPORTANT
Precaution against chemicals:
Operate chemical injection systems by strictly following the

instruction of the chemist. The operator must use suitable
protective tools.
Disposal:
Observe the rules and regulation of the installation site.
Material Safety Data Sheet (hereafter MSDS):
Always understand the content of the applicable MSDS

before using, and observe the notified instructions when
handling the chemical.
Emergency response:
Solution against emergency must be thoroughly instructed

to all personnel involved so that the fullest measures can be
taken against any situation.
1.4.2.7
Cautions against Combustible Materials/ Storage

Areas
IMPORTANT
Storage containers must be clearly marked to indicate the
content.
Bunding must be provided for bulk tanks.
Suitable fire protection must be provided for each area.
Do not store bulk combustible materials on the site.
Small quantities of combustible materials must be stored in

fire resistant cupboards.
Combustible materials must be segregated from other

equipment.
MM-M05.02
Rev.001

Mitsubishi
1-14
Chapter 1
1.4.2.7
Safety
Cautions against Combustible Materials / Storage

Areas (Continued from previous page)
IMPORTANT
Leakage of gasoline has the risk of fire. Maximum storage

quantity of gasoline outside of the dispensing pump is five
liters.
Emergency response:
Personnel directly involved in combustible materials MUST

be properly trained and thoroughly instructed. Other
personnel in the vicinity must be aware of the dangers and
take precautions in all situations.
1.4.2.8
Cautions against Lack of Oxygen
Check that the oxygen content in the equipment vessel or in

the confined space is between 18~22% before entering, and
ensure sufficient ventilation.
Continue monitoring oxygen and ventilation during

inspection.
It is recommended that you do not enter the equipment,

vessel or confined space alone but if the situation demands
that you must enter, take the necessary preventive safety
measure provided, breathing system etc, and find a partner
who will wait for your return at the point of entry, keeping in
verbal contact throughout.
Make complete arrangements for rescue.
MM-M05.02
Rev.001

Mitsubishi
1-15
Chapter 1
1.4.2.9
Safety
Cautions against Lifting Heavy Object

Be careful during the removal/installation of any equipment
during maintenance.
CAUTION
Do NOT attempt to move or lift equipment in an abnormal

posture. ALWAYS install/remove equipment, using a forklift
or a crane. A normal lift without mechanical aid should be
shared between two or more persons.
Failure to observe the above may cause injury due to

dropped equipment, back or waist injury or damage to the
equipment.
1.4.2.10
Cautions against Sharp Objects
CAUTION
1.4.2.11
Use leather gloves when handling parts with sharp edges.
Cautions using Fork Lift
MM-M05.02
Rev.001
CAUTION

Mitsubishi
Do NOT permit anyone to stand below any item being lifted

under any circumstance.
Failure to observe this may cause fatal accidents.
When using a forklift, ALWAYS lift the objects parallel to

the ground while considering the center of gravity.
Otherwise, lifted objects may fall and serious damage

could occur.
A forklift is often used to transfer small machines. Check

fork insertion position for the forklift prior to use. Be
careful, as marks which indicate the fork insertion
positions are sometimes hidden by wraps or packing
materials.
1-16
Chapter 1
1.4.2.12
Safety
Cautions using Crane
CAUTION
A crane is often used to transfer heavy parts. Check for any

possible risks which could occur during hoisting and
transportation before operating the crane.
Check of the equipment:
Check the crane, the crane hook and all related items
before use. Use wire ropes which can withstand the weight
of the parts multiplied by a safety factor.
Inspect the shackles, eyebolts, jigs and wire ropes

provided for the hoisting work prior to the actual hoisting.
Perform periodical inspection (dye penetrant test) of

hoisting tools at least once a year.
Rigging / Slinging work:
Only authorized personnel can perform slinging work and

operation of the crane.
Work area:
Before hoisting, secure a working area around the part to

be lifted and prohibit the entry of unrelated personnel.
Hoisting method:
Hoist the part parallel to the ground while paying attention

to the center of gravity.
Do NOT permit any person to stand under the part being

lifted.
Pay attention to and ensure that all persons are clear of the
equipment being lifted.
Hoisting point:
Do NOT hoist any parts from a position other than the

specified hoisting points.
Unpacking:
Do NOT unpack any part until it is located in the
designated location.
Protection of machine:
Avoid any impact to the unpacked parts.
MM-M05.02
Rev.001

Mitsubishi
1-17
Chapter 1
Safety
1.4.2.13 Disposal
a)
Water disposal including oily drain

The water is disposed to the plant drain system. The water must be
carefully disposed according to materials contained in the water. The
water drain system is separated into three categories that are rain
water, chemical water and oily water.
The waste waters are treated and then discharged to the public drain
system.
b)
Chemical disposal
Chemicals must be handled following the instruction of the MSDS
and disposed to the chemical drain system.
c)
Solid disposal made by maintenance work.
MM-M05.02
Rev.001
For disposal from the site, observe the local legal regulations.

Mitsubishi
1-18
Chapter 1
1.5
Safety
Emergency Measure
1.5.1 Evacuation on Emergency Case
1.5.1.1
Evacuation Route
Following items are considered on design and installation of
emergency evacuation.
IMPORTANT
Each building installed in the plant is provided with at least two

exits. A clear indication of the exits can be seen from anywhere
in the building as the exit sign is illuminated using the
emergency power supply.
Evacuation routes are indicated on each floor of the building,

directing personnel to the exits.
Keep the evacuation routes completely free from materials and

tools.
1.5.1.2
Evacuation of Disabled Persons Who Cannot

Move by Themselves
The following are necessary items, prepared for emergency
evacuation:
IMPORTANT
It is recommended to keep a stretcher available for
emergencies at the places selected as being secure at the
safety meeting.
If you find this kind of accident, inform the rescue team, and
attempt to bring the collapsed person to the first aid station.
MM-M05.02
Rev.001

Mitsubishi
1-19
Chapter 1
1.5.1.3
Safety
Evacuation from Power House

Following are guidance for the evacuation from the power
house.
IMPORTANT
An evacuation place for personnel to gather in after

evacuation from the power house in an emergency must be
predetermined and explained beforehand in the emergency
training.
Evacuation directive must be given by the responsible

person such as Shift Charge Engineer, and all personnel
must be alerted in the power house repeatedly with an
available broadcast facility.
All people working in the power house must stop their work
immediately and leave the power house to the gathering
place.
When evacuated to the evacuation place, make sure

that there is no one missing.
MM-M05.02
Rev.001

Mitsubishi
1-20
Chapter 1
Safety
1.5.2 Fire Accident
IMPORTANT
Clearly show the location of fire alarm push button and fire
extinguisher to make everybody take the first step at fire
protection.
Inform everyone concerned that a fire has now started if

you discover a fire.
Start fire fighting using the fire extinguisher located near

the fire site.
The operators must check the plant is ready for trip, and
wait for order from the responsible person.
The operator and other personnel must transfer the fire

fighting to the fire fighting team when they arrive at the fire
site and the operators must wait for instruction from the
Shift Charge Engineer. All other personnel must
immediately start evacuation.
If unit trip is decided, the operator must trip the plant

manually.
The operators must evacuate from the power house

according to the instruction of the responsible person
immediately after shutdown of the unit.
If the fire is extinguished successfully, the operators

should return to the power house as required by the Shift
Charge Engineer and start inspection of the equipment for
restart of the unit.
Based on the inspection, the responsible person should

decide whether to operate the unit again or shutdown for
repairing.
After the inspection or repair, and then checking the

equipment and/or system, start up the unit again.
MM-M05.02
Rev.001

Mitsubishi
1-21
Chapter 1
Safety
1.5.3 Earthquake
In the case of an earthquake, the shift charge engineer or operator must
judge whether the unit trip is necessary according to the intensity of the
earthquake, and immediately trip the unit manually. If the unit is tripped, all
equipment must be carefully checked on its operation status and tripped if
abnormal phenomena are found.
In the local area, mechanical and/or thermal shocks may be given to the
equipment, piping, instruments and electrical panels. Be sure to observe
the following when completing the inspection.
Check that the lubricating oil pump is running. Bearings of

the equipment will be damaged if lubricating oil is not
supplied.
Check the piping and equipment for steam and water

leakage. The steam or high temperature water leakage may
cause serious injury to the personnel and it must be
repaired at an early stage of the leakage.
Check the pulverizers and/or coal silos for signs of a fire. If

a coal fire does start, make sure that the CO 2 fire fighting
system is properly operated.
Check the position of boiler seismic stopper. Since the

boiler seismic stopper must be anchored at the original
position, the boiler cannot be re-started if the slippage is
found. If the stopper is not at the original position, please
contact MHI.
CAUTION
Check the piping and equipment for the breaking and the
dropping of insulation. Since the exposure of the hot
surface may cause burn injury, it must be repaired by a
worker fully dressed in Personal Protective Equipment.
MM-M05.02
Rev.001
1.5.4 Explosion Accident

Mitsubishi
Do not use a fire in a hazardous area where the combustibles

(hydrogen gas, oxygen gas, coal, fuel oil, etc.) are stored or
handled. Use of a fire in a hazardous area could cause
serious injury to personnel and serious damage to
equipment due to an explosion.
1-22
Chapter 1
1.6
Safety
Qualification and Training

The system must be operated only by authorized operators & maintenance
supervisors.
The customer shall authorize all operators and maintainers, who are involved in the
operation and maintenance of this plant, either by the training course given by
Mitsubishi, or by customers own personnel assessment.
Operator and maintainer training course (both classroom training and On the Job
Training (OJT)) will be provided by Mitsubishi before the handing over of this plant.
The customer must train and assess new operators and maintainers who join after
the turn-over according to his own procedure and standard, (Mitsubishi training
course may still be available if required).
As a minimum, operator and maintainer must satisfy the following:
Operator and Maintainer can read and fully understand the description of this
manual.
Operator and Maintainer can understand the related P & ID, logic diagram.
Operator and Maintainer know the location of the system equipment including
pipe routes, valves and the various instruments.
Operator and Maintainer have fundamental knowledge of the function of each

equipment.
Operator can operate the equipment and the system manually at local stations.
Operator can operate the system remotely using DCS system.
Operator can respond suitably for any kind of alarm.
Operator knows location of emergency exit on power house and is available to

provide first aid treatment.
Operator knows emergency communication system operation.
Operator and Maintainer know isolation method for mechanical, electrical and
instrumental equipments for maintenance work during plant operation.
Maintainer must also be able to handle the maintenance tools provided by the
owner and those supplied by the manufacturer.
MM-M05.02
Rev.001

Mitsubishi
1-23
Chapter 2 General
C h a p t er
2 General
2.1
Purpose
The purpose of this maintenance manual is to provide specific information to the
Paiton Expansion Project maintenance personnel regarding the maintenance of
the steam admission valves, their actuators and servo systems. Although this
document will convey a good knowledge and direction regarding maintenance
of the steam admission valves and their servo-systems, it is recommended that
in the event of a problem not covered in the document the person responsible
should seek assistance or instruction from the turbine manufacturer.
References
a)
Steam Turbine Sectional Assembly

MHI Dwg. No: T3059AAAA001
Project Dwg. No: P101-50-3-TB-TGO003
b)
Turbine and Generator Outline

MHI Dwg. No: T3059AAAA003-1
Customer Dwg. No: P101-50-3-TB-TGO001
c)
Turbine and Generator Outline

Customer Dwg. No: P101-50-3-TB-TGO002
d)
Control and Lubrication Oil System Diagram

Project Dwg. No: P101-51-3-TB-LT-O001
e)

f)

MHI Dwg No: T3059AAAA210-3
g)

f)

MM-M05.02
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2.2

Mitsubishi
2-1
Chapter 2 General
Gland Steam and Drain Piping Diagram (1/4)

Project Dwg. No: P101-51-3-TB-TLO001
h)
Gland Steam and Drain Piping Diagram (2/4)

Project Dwg. No: P101-51-3-TB-TLO002
i)
Main Stop Valve Assembly (1/3, 2/3, 3/3)

MHI Dwg. No: T3059TS1E011-1~3
Project Dwg. No: P101-50-3TB-TG-O017~019
j)
Main Stop Valve Actuator Assembly

MHI Dwg. No: TJ80E-000012
k)
Governing Valve Assembly (1/3, 2/3, 3/3)

MHI Dwg. No: T3059JG1E011-1~3
l)
Governing Valve Actuator Assembly

m)
MSV & GV Support Assembly (1/3, 2/3, 3/3)

MHI Dwg. No: TG2DE-000003
n)
RSV & ICV Assembly

MHI Dwg. No: T3059KC2E001
o)
Reheat Stop Valve Assembly

MHI Dwg. No: T3059KS1E011-1~3
p)
Reheat Stop Valve Actuator Assembly

MHI Dwg. No: TJA0E-000001
q)
Interceptor Valve Assembly

MHI Dwg. No: T3059KG1E11-1~3
r)
Interceptor Valve Actuator Assembly

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Rev.001
g)

Mitsubishi
2-2
Chapter 2 General
2.3
Overview of Turbine Steam Admission Valves

Refer to Figures 2-1 to 2-4.
The main turbine unit is a three-cylinder tandem compound, quadruple exhaust,
condensing reheat turbine, designed for high operating efficiency and maximum
reliability. The turbine receives superheated main steam at 24.5 MPa(a) and
538C and reheated steam at 4.7 MPa(a) and 566C. It rotates at a speed of
3000 rpm and generates 815 MW of electricity through a generator coupled to
the turbine rotor.
The main turbine consists of three cylinders arranged in a line and coupled
together. The three cylinders consist of a combined high pressure (HP) and
intermediate pressure (IP) cylinder viz. HP-IP cylinder and two low pressure
(LP) cylinders. Steam flows to the turbine cylinders are controlled by two sets of
main stop valve (MSV) and governing valve (GV) assemblies and two sets of
reheat stop valve (RSV) and interceptor valve (ICV) assemblies.
Main steam enters the HP element of the HP-IP turbine through two steam
chest assemblies each consisting of one MSV and two GVs. Steam flow to the
HP turbine is controlled and regulated by the MSVs and the GVs.
The steam chest assemblies are located one on each side of the HP-IP turbine.
The GV outlets are connected to the HP element of the HP-IP casing through
four inlet pipes. Each inlet pipe is connected to its nozzle chamber by a slip joint.
Two of these inlet steam pipes are connected to the upper casing and the
remaining two to the lower casing.
Steam enters the steam chest at one end and passes through the MSV into the
main section of the steam chest where the GVs are located. From the steam
chests steam passes through the GVs and enters the HP turbine through the
four turbine steam inlets. The rate of steam flow leaving the steam chests and
passing to the HP turbine is determined by the position of the turbine GVs.
The turbine steam admission valves are operated individually by hydraulically

powered actuators through a digital control system.
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Steam from the HP turbine exhaust (cold reheat) line is directed to the boiler to
increase the potential energy by heating it to an elevated temperature. In the
reheater the cold reheat steam temperature is increased and the reheated
steam is returned to the IP element of the HP-IP turbine through two sets of
RSV/ICV assemblies, each consisting of one RSV and two ICVs. The RSV/ICV
assemblies are installed one set on each side of the HP-IP turbine casing. The
four outlets from the ICVs are connected to the IP element of the HP-IP upper
and lower casings. Steam flow to the IP turbine is controlled and regulated by
the RSVs and the ICVs.

Mitsubishi
2-3
Chapter 2 General
The MSVs, GVs and ICVs are provided with servo-type actuators as these
valves require control function as per the operational requirement. These
actuators control the supply of hydraulic fluid to the hydraulic cylinders and allow
accurate position control of the valves. The RSV actuators do not have
servo-mechanisms, as they require only open and close position controls. They
are operated directly by the line hydraulic fluid pressure.
A Digital Electro-Hydraulic (DEH) control system provides control signals for
positioning the steam admission valves as per the turbine load. A servo-valve is
provided separately for each MSV, GV and ICV. The servo-valve converts the
electronic signal into hydraulic output which operates the hydraulic actuator
power cylinder to actuate the respective valve stem.
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Hydraulic power for the actuators is provided by an EH fluid supply skid. This is
a storage, conditioning and pumping facility providing synthetic oil for hydraulic
operation of the turbine steam admission valves. The synthetic oil used is
selected for its fire resistance capability.

Mitsubishi
2-4
General
Rev.001
Chapter 2
MM-M05.02
MPTD-3-0951
FIGURE 2-1

Mitsubishi
ISOMETRIC VIEW OF THE TURBINE AND STEAM ADMISSION VALVES
2-5
General
MM-M05.02
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Chapter 2
FIGURE 2-2

Mitsubishi
HP TURBINE STEAM ADMISSION VALVES ASSEMBLY
2-6
Chapter 2
General
LVDT
SPRING HOUSING
STEM LEAK-OFF
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STEAM OUTLET
( TO IP TURBINE )
MPTD-3-0953
FIGURE 2-3

Mitsubishi
IP TURBINE STEAM ADMISSION VALVES ASSEMBLY
2-7
Chapter 2 General
2.4
Construction and Arrangement

2.4.1 HP Turbine Steam Chest and Steam Admission
Valves
Steam Chest
Refer to Figures 2-4 and 2-5.
The steam chest is made of a hollow cast steel body with three
openings, one opening at the steam inlet end for the installation of the
MSV and two on the top for the GVs. The steam chest also has three
integrally cast nozzles on the underside; one for the entry of inlet steam
to the MSV and two for the exit of steam from the GVs to the turbine.
Each steam chest is mounted on two base plates with a flexible
supporting system. The supporting system is installed in such a way
that the thermal movements are accommodated without the need of a
sliding foot arrangement.
Each steam chest assembly has two supports; the front and the rear.
The front support is bolted to the sides of the steam chest (1) at the
steam inlet end. The rear support is bolted to the end opposite to the
MSV, the governor end (Gov End). The steam chest supporting
arrangement is made rigid using two stiffener plates (9) bolted to the
feet of the supports.
The bases of both the vertical and the longitudinal support brackets are
bolted to the steam chest base plate (5). The base plate is located
within a steel frame (6) arrangement which is secured to the turbine
foundation. Bolts screwed onto both sides of the base plate locate the
base plate in position. The bolt heads of these locating bolts are so
adjusted to grip tightly with the sides of the steel frame.
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The front support consists of two fixed support brackets (2), one bolted
to each side of the steam chest. The steam chest is provided with slots
at both sides at the supporting locations which engage with matching
tongue/projection to the support brackets. This support locates the
steam chest assembly axially and allows expansion of the steam chest
on the longitudinal axis. A tie rod (10) and sleeve (11) support
arrangement, bolted to the bottom of the steam chest with a tongue
and groove fit, acts at the longitudinal center line and provides lateral
location. Another support bracket (4) secured to one end of the tie rod
(10) and bolted to the support base plate (5) provides rigidity to the
bottom support.

Mitsubishi
2-8
Chapter 2 General
The rear support consists of a fabricated steel structure and is bolted to

the Gov End of the steam chest. The vertical plate of the support
bracket (3) is provided with a cold spring of 131 mm to enable the
support to become vertical during hot condition. The base of the rear
support bracket is bolted onto another base plate (8). This base plate is
also located within a steel frame (7) which is secured to the turbine
foundation.
Bolts screwed onto the base plate at three sides locate the base plate
in position. The bolt heads of these locating bolts are so adjusted to
grip tightly with the sides of the steel frame.
Main Stop Valve

Refer to Figure 2-6.
The MSVs are of the double seat plug valves type, installed in a
horizontal position directly into the steam chest, such that the inlet end
of the steam chest forms the valve body.
The MSV assembly consists of a pilot valve (4), operating within a main
valve (3). The inlet port for the pilot valve is provided by seven ports
(one horizontal and six angled) drilled circumferentially at the top
surface of the main valve. The outlet port is provided by drilling an
opening in the center of the main valve disc. The inside surface of the
pilot valve outlet port is profiled to provide a seat for the pilot valve in
the closed position.
The pilot and main valves are operated by a common stem (9) which is
located and guided by four bushings within the valve [lower stem
bushing (13), intermediate stem bushing (14) and upper stem bushing
(15) and bonnet bushing (16)]. The lower portion of the stem is made
hollow and a spring (8) is installed inside which exerts a constant force
to the pilot valve through a spring seat (6). A valve nut (5), inserted
through the stem from top side, retains the pilot valve in position with a
loose fit during valve operation. The pilot valve is screwed onto the
valve nut and secured by caulking. The loose fit arrangement provides
a limited self alignment capability for the pilot valve.
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The mechanical arrangement between the main and pilot valves is

such that, after the pilot valve is fully opened, further actuator
movement results in the opening of the main valve and the pilot valve
together. Both valves are unbalanced.
A bonnet (22), bolted to the steam chest using stud bolts (23), guides
the valve stem during valve operation. The lower stem bushing (13),
intermediate stem bushing (14) and upper stem bushing (15) jointly
locate the valve stem and ensure smooth movement. A main valve
bushing (12) secured to the bonnet guides the main valve during
operation.

Mitsubishi
2-9
Chapter 2 General
The intermediate stem bushing (14) is screwed into the main valve (3)
and retained by peening. The lower stem bushing (13) is screwed onto
the bottom end of to the intermediate stem bushing (14) and secured
by pins (63). The upper stem bushing (15) is screwed into the bonnet
and retained by peening. The main valve bushing (12) is also secured
to the bonnet by peening.
A spring housing (29) containing a set of pre-compressed springs (33)
is mounted on the valve bonnet. A connecting rod (40), operated by the
MSV actuator (62), passes through the spring housing and compresses
the springs during its upward movement through a lower spring seat
(31) and spring guide (32). A spring guide rod (21) secured to the
connecting rod (40) provides support to the spring guide (32).
The bottom end of the spring guide rod is guided into the bonnet by a
bonnet bushing (16). The bonnet bushing is secured to the bonnet (22)
by retaining bolts (17). The spring guide rod (21) and the valve stem (9)
are secured together with a lock pin (19). The movement of the spring
guide rod by the actuator raises or lowers the valve stem. Reverse
movement of the connecting rod releases the compression of the
springs.
The springs apply a continuous closing force to the valve stem and the
main and pilot valves by virtue of the spring compression force. Spring
compression bolts (39) provided below the lower spring seat (31) when
tightened releases the compression force from the connecting rod thus
making the valve stem free. The spring compression bolts are to be
removed after completion of maintenance work. A guide plate
arrangement (60, 61) secured to the upper spring seat (30) of the
spring housing guides the connecting bar during operation.
The upper end of the connecting rod is connected to an operating lever
(44), which is formed by bolting together two identical levers into a
single lever. One end of the operating lever is connected to the actuator
piston rod and the opposite end to a stay link (54). The other end of the
stay link is secured to the spring housing.
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A limit switch assembly (55) is mechanically connected to the valve

operating lever (44) through a linkage (55). The activation of the limit
switch lever operates multiple microswitch contacts which provide
various function signals for the valve.
An LVDT assembly (57) secured to the actuator is connected to the
actuator piston rod through another linkage (58). The LVDT indicates
the position of the MSV continuously in the CCR.
When in the closed position, the force produced by the inlet steam
pressure acting on the main valve and the force exerted on the valve
stem by the closing springs, combine to hold both the main and pilot
valves firmly on their seats.

Mitsubishi
2-10
Chapter 2 General
High pressure hydraulic oil is supplied to the actuator to open the valve.
This produces a lifting force which overcomes the spring pressure
holding the pilot valve in the closed position. As the pilot valve stem
rises, the pilot valve is lifted from the seat and steam is admitted to the
steam chest through the pilot valve port. The admission of steam into
the steam chest starts the process of equalizing steam pressure either
side of the main valve, thereby progressively reducing the closing
force.
As can be seen in Figure 2-6, the area on which the steam pressure
acts to apply a force to open the main valve is greater than the area on
which it acts to apply a force to close the valve. For this reason, even if
the forces acting on either side of the main valve become equal, there
will be still a differential pressure across the valve.
As the pilot valve reaches the fully open position within the main valve,
the step on the valve stem (9) makes contact with a matching face
(back seat) at the bottom end of the intermediate stem bushing (14).
Further actuator movement will open the main valve.
The MSV has a combination of features to prevent steam leakage
along the valve stem during full open and close positions. When the
main valve is in the fully open position, the intermediate stem bushing
(14) and the upper stem bushing (15) come into contact to form a
back-seat sealing joint, thus preventing steam leakage along the valve
stem.
A second internal seal is provided between the upper face of the upper
stem bushing (15) and the lower face of the spring guide rod (21). The
purpose of this seal is to isolate the valve internal steam space from the
leak-off connection lines when the valve stem is in the closed position.
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The bonnet bushing (16), secured to the top of the bonnet (22) where
the stem penetrates the bonnet, prevents steam leakage along the
stem to atmosphere.
The valve stem is provided with spiral grooves on the periphery in the
vicinity of the lower, intermediate and upper stem bushings to provide a
continuous leakage of steam along the stem, which serves as a
lubricant for free movement of the stem. A passage is drilled in the
bonnet above the upper stem bushing to provide a high pressure (HP)
leak-off connection (28) which drains the steam leaking through the
clearance between the stem and the upper stem bushing. Another
passage is drilled above the HP leak-off connection and matching
passages drilled in the bonnet bushing to provide a low pressure (LP)
stem leak-off connection (59) which drains the steam leaking through
the clearance between the stem and the bonnet bushing. The HP
leak-off connection vents the leakage steam to the No. 6 extraction
steam line and the LP leak-off connection vents to the gland steam
condenser.

Mitsubishi
2-11
Chapter 2 General
A steam strainer (10), provided concentrically around an integral

cylindrical lip at the bottom of the bonnet within the MSV, filters the
incoming steam before entering the valve inlet steam space. This
permanent strainer is made of a 25.5 mm thick stainless steel plate with
uniformly drilled 7 mm holes and is secured to the bonnet by welding. A
fine mesh temporary strainer (11) is provided around the permanent
steam strainer for use during initial commissioning stages of the turbine.
The temporary strainer is made of a 3 mm thick stainless steel plate
with uniformly drilled 4 mm holes and is secured to the permanent
strainer with countersunk screws. The purpose of the temporary steam
strainer is to screen out debris from entering the turbine during the
preliminary operation period.
Note
The fine mesh temporary steam strainer is not designed for long
life operation and is intentionally susceptible to becoming
clogged with debris during preliminary operation. Therefore, it is
recommended to inspect and remove the temporary strainer
within ninety (90) full days of service. This period is to include
operation for a period of not less than four (4) days with full
volumetric steam flow.
Temporary strainer operation should not extend beyond these
recommended limits, as failure of the temporary strainer could
cause severe damage to the MSV. Also excessive blockage results
in a restricted steam flow passage.
MSV Actuator Assembly

The function of the MSV actuator assembly is to open the MSV as
required at turbine startup. It operates the valve via a mechanical lever
which is part of the valve head gear.
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The MSV actuator assembly consists of the following major

components:
z
Hydraulic cylinder
Servo valve
Dump valve (Pressure relief valve)
Accumulator
LVDT
Isolation valve

Mitsubishi
2-12
Chapter 2 General
Check valves
Filter.
Within the actuator assembly itself, hydraulic oil passes through the
isolation valve and the filter to the servo-valve. The servo-valve directs
the high pressure hydraulic fluid to the actuator hydraulic cylinder inlet
port. The outlet port of the hydraulic cylinder is connected to drain.
The functions of the main components of the MSV actuator assembly
are as follows:
a)
Hydraulic Cylinder
The MSV actuator hydraulic cylinder is of the single acting piston
type.
The hydraulic cylinder consists of a cylindrical housing (1) which
contains the piston and piston rod assembly. The piston is
provided with O-ring and piston rings in slots at the inner and
outer surfaces to prevent leakage of oil through the piston. End
covers fitted at the ends of the hydraulic cylinder contain ports for
the passage of the inlet and return oils. The end-cover fitted at
the piston rod end has opening for the traverse of the piston rod.
The piston rod end-cover is provided with a slot to install a
bushing which guides the movement of the piston rod (12). The
bush has internally machined grooves to provide lubrication for
smooth movement of the piston rod.
A seal casing (13) fitted to the piston rod end cover contains two
oil seals to prevent oil leakage along the piston rod. Internal
passages drilled in the seal cover connect any passing leakage
oil to the drain line.
The end of the piston rod (12) protruding out of the hydraulic
cylinder is fitted with a clevis (19) which is connected to the MSV
operating lever.
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Springs in the valve head gear apply a continuous closing force

to the valve stem. When hydraulic fluid pressure is applied to the
actuator through the inlet port, it opens the valve against the
spring force. A controlled oil pressure positions the valve in the
required position. The quick release of oil pressure during a
turbine trip command closes the valve instantaneously by the
springs.
The MSV hydraulic cylinder is adjusted for 6.1 mm over-travel to
enable the valve to close tightly on the seat.

Mitsubishi
2-13
Chapter 2 General
b)
Servo Valve
The function of the servo valve (7) is to supply oil to the hydraulic
cylinder as per the signal from the turbine control system.
The servo valve consists of a main valve and an electrically
operated pilot valve. The pilot valve receives electrical signal
from the turbine control system which moves a control spool
within the main valve. This spool movement directs the E/H
supply oil to the inlet port of the hydraulic cylinder.
The servo valve is provided with a built-in filter at the entry point
to protect the inlet orifices and nozzles against dirt particles.
c)
Dump Valve
The function of the dump valve (6) is to release the hydraulic fluid
pressure from the hydraulic cylinder resulting in instantaneous
closure of the MSV.
The dump valve consists of a main valve with a spring loaded
piston and a pilot valve with a spring loaded plunger. An orifice
opening drilled in the dump valve piston supplies restricted fluid
from the upstream to the downstream (piston spring side) of the
piston. The downstream side of the dump valve piston is
connected to the emergency trip oil line through a check valve.
Another opening drilled on the dump valve body directs the fluid
to the drain when the piston is opened. The fluid pressure
downstream of the dump valve can be adjusted manually by an
adjusting screw arrangement provided on the pilot valve which
relieves the excess fluid to drain.
During normal operation, the dump valve piston is hydraulically
balanced and kept closed by the piston spring pressure. Full
hydraulic pressure is therefore available to the MSV actuator.
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Operation of any of the turbine trip protective functions will

release the pressure in the emergency trip oil line causing the
hydraulic fluid on the spring side of the dump valve piston to be
drained away.
As the pressure drop in the emergency trip oil line is greater than
the capacity of the orifice in the dump valve piston, the dump
valve piston will become hydraulically unbalanced. The dump
valve piston will open against the piston spring pressure and
allow the hydraulic fluid from the actuator cylinder to drain
through the downstream passage. This drainage of fluid from the
hydraulic cylinder causes the instantaneous closure of the MSV.

Mitsubishi
2-14
Chapter 2 General
The pilot valve can be operated manually for valve testing

purposes. At such times the actuator fluid isolation valve would
be closed.
Manual operation of the pilot valve will release the hydraulic
pressure on the spring side of the dump valve piston. The orifice
in the dump valve piston causes a slow decay of pressure
throughout the hydraulic system downstream of the isolation
valve. However the dump valve piston will not be able to open
against the spring pressure. Thus, the gradual pressure decay
will close the MSV in a controlled manner.
d)
Accumulator
The MSV actuator assembly is provided with a piston type
accumulator (4) installed on the drain side of the hydraulic
cylinder.
The purpose of the accumulator is to limit the pressure rise on the
low pressure side of the actuator hydraulic cylinder during high
speed closure of the MSV. The pressure at the downstream of
the hydraulic cylinder would be a factor which would tend to
reduce the speed at which the valve could close. The
accumulator absorbs the sudden high flow of oil and maintains a
near-constant drain line pressure during an instantaneous valve
closure.
The accumulator consists of a cylinder with an inlet port which is
connected to the hydraulic cylinder drain line. A piston with
sealing rings is installed in the accumulator cylinder. The
accumulator is filled with N2 gas at 0.7 kg/cm2 on the gas side.
The accumulator provided for the MSV actuator is of 2 liters
capacity.
When there is a sudden oil flow, the N2 gas gets compressed and
the accumulator absorbs the excessive flow and maintains the
drain line pressure.
e)
LVDT
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The MSV actuator is fitted with a linear variable differential

transformer (LVDT) for the remote indication of the valve position.
The LVDT is an electro-mechanical transducer which functions
as a position signal generator.
The LVDT is mounted on the MSV actuator and is connected to
the actuator operating linkage. It moves parallel to the actuator
(and MSV) and produces an electrical signal proportional to the
MSV position.

Mitsubishi
2-15
Chapter 2 General
The signal from the LVDT is converted to DC by a demodulator

and then fed back to the DEHC system to control the
servo-amplifier.
f)
Isolation Valve
An isolation valve is installed in the hydraulic oil supply line
before the oil filter to isolate the high pressure oil to the servo
valve. This enables maintenance work on the filter, the
servo-valve and the dump valve to be performed while the turbine
is in operation. However, to perform the above maintenance work
the corresponding MSV must be taken out of service resulting in
an approximate 50% load reduction.
Note
To ensure safety (whenever possible), MHI recommend that the
above maintenance should be performed when the turbine is shut
down.
Note
A major cause of servo valve and relief valve problems is the
deterioration of the high pressure EH oil condition due to poor
management of the oil conditioning system. So, any maintenance
on the servo-system can be minimized by maintaining the oil in
good condition by good management of the EH oil conditioning
system.
g)
Check Valve
Three spring loaded poppet type check valves are installed in the
MSV actuator assembly. One check valve is installed in the
common drain line in which drains from the hydraulic cylinder, the
dump valve and the servo valve are collected. Two check valves
are installed in the emergency trip oil line, one valve at the outlet
of the dump valve and the other valve in the common emergency
trip oil line.
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The main function of the check valve is to prevent reverse flow of

fluid from other parts of the hydraulic system, which could
interfere with maintenance activities and operational tests. It also
retains fluid pressure at the downstream side of the hydraulic
cylinder and the dump valve to provide cushion/back pressure to
prevent bumpy operation within the hydraulic cylinder.

Mitsubishi
2-16
Chapter 2 General
h)
Filter
A 10 micron stainless steel mesh filter is installed in the supply
line before the servo valve. The purpose of the filter is to remove
particulate contamination from the hydraulic fluid thus protecting
the servo-valve from mal-operation. The filter should preferably
be replaced when blocked. However it can be cleaned as per the
guidelines provided in Section 4.2.2.
Governing Valve
The GVs are hydraulically operated globe valves installed on the top of
the steam chest. The GVs control the outlet steam from the MSV and
direct it to the HP element of the HP-IP cylinder through the outlet loop
pipes.
Each GV assembly mainly consists of a stem assembly, a bonnet
assembly, a spring assembly, a linkage mechanism and a hydraulic
actuator assembly.
The stem assembly consists of a valve stem (2), a main valve (plug) (3)
and a valve nut (4). The valve nut is inserted from the top of the stem
and the main valve is screwed onto the valve nut from below. A
stepped projection at the lower end of the valve stem retains the valve
nut. After tightening, the main valve is secured to the valve nut using
four retaining pins (5) to prevent loosening during operation. The
retaining pins are peened after final installation to prevent loosening
during operation.
The valve stem above the valve nut is guided by two bushings secured
to the valve bonnet, the lower stem bushing (6) and the upper stem
bushing (7). The valve stem is provided with spiral grooves on the
periphery where the stem enters and exits these bushings for smooth
traverse. The grooves near the lower stem bushing provide a
continuous leakage of steam along the stem. This leakage steam
serves as a lubricant for free movement of the stem. Passages drilled
on the main valve (3) and the lower part of the stem (2) provides steam
supply for lubrication when the valve is in the open position.
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The lower end of the valve stem assembly is installed within a flow
guide (12) secured at the lower end of the valve bonnet (8). The valve
stem assembly is installed within the flow guide with a close clearance
between the flow guide (12) and the valve nut (4). This clearance
enables the valve stem assembly to traverse within the flow guide with
a limited self alignment capability.

Mitsubishi
2-17
Chapter 2 General
The bonnet assembly consists of the bonnet (8), the flow guide (12)
and the two stem bushings (6 and 7). The flow guide and the stem
bushings jointly guide the stem assembly during valve operation. The
flow guide is inserted into the lower end of the bonnet and retained by
four pins (61) inserted laterally through four holes in the bonnet. (Refer
to Detail A in Figure 2-9). The flow guide pins are peened to prevent
them from loosening after final installation. The lower stem bushing (6)
is screwed into the lower end of the bonnet bore and retained by
caulking. The upper stem bushing (7) is inserted into the upper end of
the bonnet bore and retained by six retaining screws (15).
The bonnet assembly is bolted to the steam chest (1) at the top using
stud bolts (9) and nuts (10). These stud bolts are provided with heater
elements to heat and stretch them during installation and valve
disassembly. A spiral wound gasket (60) installed between the steam
chest and the bonnet provides sealing for the flanged joint.
The bonnet flange is provided with three jacking bolt holes for jacking
during disassembly and for controlled lowering of the bonnet assembly
during reassembly. The flange is also provided with three eye bolt
holes for handling the bonnet assembly.
Passages are drilled in the bonnet flange to provide high pressure (HP)
stem leak-off connection (14) and low pressure (LP) stem leak-off
connection (65). The HP (lower) leak-off connection (14) vents leakage
steam at the downstream of the lower stem bushing (6) to the No. 6
extraction steam line. The LP (upper) leak-off connection (65) vents
leakage steam through the upper stem bushing (7) to the gland steam
condenser.
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A spring housing (23) is mounted on top of the bonnet (8) using stud
bolts and nuts (24, 25) and contains a set of pre-compressed springs
(33). The springs are held between a fixed upper spring seat (31) and a
movable lower spring seat (32). Spherical washers (29) and a liner (28)
provided below the lower spring seat move as a single unit with the
lower spring seat and the connecting rod (22) during valve operation.
The lower spring seat (32) compresses the springs (33) during its
upward movement by the GV actuator (57). Reverse movement of the
actuator releases the compression of the springs. The springs apply a
continuous closing force to the valve stem (2) and the main valve (3) by
virtue of the spring compression force. Four spring compression bolts
(34) are screwed onto the base plate of the spring housing (23). The
spring compression bolts release the compression force on the valve
stem when tightened thus making the valve stem free.
A bushing (27) secured to the base plate of the spring housing with a
fine clearance guides the connecting rod (22) and ensures smooth
movement.

Mitsubishi
2-18
Chapter 2 General
A special nut (16) is secured to the top end of the valve stem (2) using
a pin (20). The bottom end of the connecting rod (22) is located over
the special nut (16) using two locating pins (21). A coupling (17)
inserted from the top end of the connecting rod and screwed onto the
special nut connects the connecting rod and the special nut together.
The coupling is locked with a lateral set screw (18) after final tightening.
The coupling enables the valve stem and the connecting rod to move
as a single element.
A knuckle (40) connects the connecting rod (22) with the operating
lever (41). The knuckle is connected to the valve operating lever using
a linkage pin (50) and a bushing (59). The knuckle is screwed onto the
top end of the connecting rod and secured by a lock pin (62).
A support bracket (58) is welded to the spring housing (23) for
mounting the GV actuator (57). The long arm of the operating lever (41)
is connected to the hydraulic cylinder piston rod through a link (45). The
short arm of the operating lever is connected to another bracket welded
at the opposite end through a stay link (44). All linkage joints are
provided with linkage pins (46 / 48 / 52 / 54), bronze or DU bushings
(47 / 49 / 53), washers and split pins for smooth movement and easy
removal.
The long arm of the operating lever (41) is connected to a limit switch
assembly (56) through a linkage mechanism (55). The movement of
the links operates multiple micro-switch contacts in the limit switch to
provide function signals for the valve.
An LVDT assembly (65) secured to the actuator is connected to the
actuator piston rod through another linkage (66). The LVDT indicates
the position of the GV continuously in the CCR.
GV Actuator Assembly
The GV actuator is also of the single acting device type. The spring
housing mounted on the valve bonnet applies a continuous closing
force to the valve stem. When hydraulic fluid pressure is applied to the
actuator it opens the valve against this spring force.
MM-M05.02
Rev.001
The major components of the GV actuator assembly are similar to

those of the MSV actuator. The only additional component provided for
GV is an electrically operated solenoid valve for the protection of the
main turbine during overspeeding.
The GV actuator is provided with a hydraulic cylinder (1), a servo-valve
(7), a dump valve (6), an accumulator (4), an LVDT, an isolation valve,
three check valves, a filter (5) and a 3-way (OPC) solenoid valve (16).
The constructional and functional features of these components except
solenoid valve are similar to those explained for the MSV actuator.

Mitsubishi
2-19
Chapter 2 General
The GV actuator is provided with a 2 liter capacity accumulator and it is

filled with N2 gas at 0.7 kg/cm2 on the gas side.
The GV actuator hydraulic cylinder is adjusted for 6+2.0/-0 mm
over-travel to enable the valve to close tightly on the seat.
The GV actuator is provided with an Overspeed Protection Control
(OPC) solenoid valve (16) to protect the turbine during overspeeding.
Two ports of the solenoid valve are connected to the servo valve supply
line and the dump valve outlet line respectively. The third port is
connected to the drain line.
MM-M05.02
Rev.001
If the OPC detects a problematic mismatch between the turbine and

generator loading, it opens this solenoid valve for a short duration (for
the duration of the transient). When the solenoid valve is operated the
supply line is isolated from the emergency trip oil line and the
emergency trip oil line is connected to the drain line. The emergency
trip oil is then released into the drain line and the dump valve is
operated to close the GV. This valve closure causes pre-emptive
reduction in steam flow to the turbine, thus reducing the risk of the
turbine overspeeding.

Mitsubishi
2-20
Rev.001
Chapter 2
General
MM-M05.02
M P T D -3 -09 5 4
FIGURE 2-4

Mitsubishi
CUTAWAY VIEW OF STEAM CHEST AND HP TURBINE STEAM ADMISSION VALVES
2-21
Chapter 2
General
GEN. SIDE
1
2
3
4
5
6
7
8
9
10
11
12
13
GOV. SIDE
3
1
STEAM CHEST
FRONT SUPPORT BRACKET
REAR SUPPORT BRACKET
BOTTOM SUPPORT BRACKET
BASE PLATE
FRONT GUIDE FRAME
REAR BASE PLATE
REAR BASE PLATE
STIFFENER PLATE
TIE ROD
SLEEVE
LINER
NUT
13 +- 1
(COLD SPRING)
3
A
4
12
12
B
2
11
13
10
MM-M05.02
Rev.001
6
MPTD-3-0955
A-A
B-B
FIGURE 2-5

Mitsubishi
ARRANGEMENT OF STEAM CHEST SUPPORT
2-22
Chapter 2
26
54
48
49
47
27
50
21
29
33
39
22
23
15
10
14
11
12
13
24
25
36
44
40
46
45
31
35
37
30
38
B
52
51
55
32
41
17
42
"D"
43
STEAM INLET
56
65
34
66
59
16
28
53
58
57
64
A-A
62
3
21
40
63
12
13
4
61
MM-M05.02
Rev.001
60
B- B
MPTD-3-0956

Mitsubishi
General
20
19
18
DETAIL "D"
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
STEAM CHEST
VALVE SEAT
MAIN VALVE
PILOT VALVE
PILOT VALVE NUT
SPRING SEAT
SHIM
SPRING
VALVE STEM
STRAINER
TEMPORARY STRAINER
MAIN VALVE BUSHING
LOWER STEM BUSHING
UPPER STEM BUSHING
BONNET BUSHING
RETAINING BOLT
PLUG
PIN
LINER
SPRING GUIDE ROD
BONNET
STUD BOLT
SPHERICAL WASHER
NUT
EYEBOLT
GASKET
HP STEM LEAK-OFF PIPE
SPRING HOUSING
UPPER SPRING SEAT
LOWER SPRING SEAT
SPRING GUIDE
SPRING
STUD BOLT, NUT
LONG BOLT
STUD BOLT
SPHERICAL WASHER
NUT
CONNECTING ROD
PIN
BUSHING
SPLIT PIN
OPERATING LEVER
SPACER
NUT
LINKAGE PIN
BUSHING
LINKAGE PIN
DU BUSHING
LINKAGE PIN
DU BUSHING
LINKAGE PIN
STAY LINK
LIMIT SWITCH
LIMIT SWITCH LINK
LVDT
LVDT LINKAGE
LP STEM LEAK-OFF PIPE
GUIDE PLATE
SUPPORT
ACTUATOR
PIN
SUPPORT FASTENERS
JACK BOLT
SCALE
C- C
FIGURE 2-6
SECTIONAL VIEW OF MAIN STOP VALVE
2-23
Chapter 2 General
MAIN STOP VALVE

LIMIT SWITCH
ACCUMULATOR
STEAM
CHECK VALVE
L.V.D.T
TO DEMODULATOR
HYDRAULIC
CYLINDER
DUMP VALVE
PISTON
+- 20mA
F
FROM SERVO
AMPLIFIER
FILTER
ACTUATOR
ISOLATION VALVE
EH DRAIN OIL
EH HP OIL
EH EMERGENCY TRIP OIL
LVDT LINEAR VARIABLE DIFFERENTIAL TRANSFORMER
MM-M05.02
Rev.001
MPTD-4-0957
FIGURE 2-7
SCHEMATIC ARRANGEMENT OF MAIN STOP VALVE ACTUATOR AND

SERVO-SYSTEM

Mitsubishi
2-24
Chapter 2
11
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
18
19
6
13 12 11 10 9 8 7 6 5 4 3 2 1
19
12
13
7
10
15
General
CYLINDER BODY
PIPE BLOCK
VALVE BLOCK
ACCUMULATOR
FILTER
DUMP VALVE
SERVO VALVE
COVER ASSEMBLY
MANIFOLD
HANDLE
TERMINAL BLOCK
PISTON ROD
SEAL CASING
TIE ROD
BOLT
'O' RING
CLEVIS
9
2
18
MM-M05.02
Rev.001
13
12
19
1
FIGURE 2-8

Mitsubishi
MSV ACTUATOR ASSEMBLY
2-25
Chapter 2
31
55
56
64
63
40
62
41
B
B
39
66
38
37
45
36
67
35
42
43
41
50
59
42
43
48
45
23
44
57
49
33
46
58
32
22
51
B-B
47
29
22
52
30
28
21
34
45
11
13
25
24
17
19
54
26
20
18
68
15
10
65
53
"D"
27
16
C-C
14
2
6
60
13
DETAIL "D"
17
16
61
19
12
"F"
STEAM INLET
MM-M05.02
Rev.001
3
2
DETAIL "F"
E-E
MPTD-3-0959
FIGURE 2-9

Mitsubishi
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
General
STEAM CHEST
VALVE STEM
MAIN VALVE
VALVE NUT
LOCK PIN
LOWER STEM BUSHING
UPPER STEM BUSHING
BONNET
STUD BOLT
NUT
SPHERICAL WASHER
FLOW GUIDE
BUSHING BOLT
SPECIAL NUT
COUPLING
SET SCREW
LOCK WIRE
LOCK PIN
LOCATING PIN
CONNECTING ROD
SPRING HOUSING
STUD BOLT
NUT
SPHERICAL WASHER
BUSHING
LINER
SPHERICAL WASHER
BOLT
UPPER SPRING SEAT
LOWER SPRING SEAT
SPRING
HEXAGONAL HEAD BOLT
SPHERICAL WASHER
STUD BOLT
SPRING WASHER
NUT
KNUCKLE
LEVER
SPACER
NUT
STAY LINK
ACTUATOR LINK
LINKAGE PIN
DU BUSHING
LINKAGE PIN
DU BUSHING
LINKAGE PIN
DU BUSHING
LINKAGE PIN
DU BUSHING
LINKAGE PIN
LIMIT SWITCH LINK
LIMIT SWITCH
ACTUATOR
ACTUATOR SUPPORT
BUSHING
GASKET
FLOW GUIDE PIN
PIN
BUSHING
SET SCREW
LVDT
LVDT LINK
SCALE
BUSHING
SECTIONAL VIEW OF GOVERNING VALVE
2-26
Chapter 2 General
GOVERNING VALVE
LIMIT SWITCH
ACCUMULATOR
STEAM
CHECK VALVE
L.V.D.T
TO DEMODULATOR
HYDRAULIC
CYLINDER
DUMP VALVE
PISTON
+- 20mA
F
FROM SERVO
AMPLIFIER
FILTER
ACTUATOR
ISOLATION VALVE
EH DRAIN OIL
EH HP OIL
LVDT LINEAR VARIABLE DIFFERENTIAL TRANSFORMER
MM-M05.02
Rev.001
MPTD-4-0960
FIGURE 2-10
SCHEMATIC ARRANGEMENT OF GOVERNING VALVE ACTUATOR

AND SERVO-SYSTEM

Mitsubishi
2-27
Chapter 2
11
13 12 11 10 9 8 7 6 5 4 3 2
12
19
13
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
19
CYLINDER BODY
PIPE BLOCK
VALVE BLOCK
ACCUMULATOR
FILTER
DUMP VALVE
SERVO VALVE
COVER ASSEMBLY
MANIFOLD
HANDLE
TERMINAL BLOCK
PISTON ROD
SEAL CASING
TIE ROD
BOLT
SOLENOID VALVE
'O' RING
CLEVIS
8
2
15
7
10
General
18
9
4
MM-M05.02
Rev.001
13
12
19
1
FIGURE 2-11

Mitsubishi
GV ACTUATOR ASSEMBLY
2-28
MM-M05.02
Rev.001
Chapter 2 General
FIGURES 2-11a

Mitsubishi
MSV PILOT VALVE CHARACTERISTIC CURVE
2-29
MM-M05.02
Rev.001
Chapter 2 General
FIGURE 2-11b

Mitsubishi
GV CHARACTERISTIC CURVE
2-30
Chapter 2 General
2.4.2 IP Turbine Steam Admission Valve Assemblies

Steam admission to the IP turbine is through two sets of RSV/ICV
assemblies, each set consisting of one RSV and two ICVs. The valve
assemblies are located one on each side of the turbine axis above the
turbine operating floor adjacent to the HP pedestal.
Each RSV/ICV assembly is supported on concrete foundations at the
13.760 m elevation of the turbine operating floor.
RSV/ICV Assembly Support

Each RSV/ICV assembly is mounted on base plates with a flexible
supporting system. The supporting system is installed in such a way
that the thermal movements are accommodated without the need of a
sliding foot arrangement.
Each RSV/ICV assembly has two supports; a front support (6) and a
rear support (7). The front support is welded to the inlet nozzle of the
RSV and the rear support to the Y-piece at the outlet of the RSV. The
supporting arrangement is made rigid by providing a stiffener plate (8)
bolted to the feet of the front and rear supports.
The front support (6) is a rigid support which consists of a support ring
welded to the inlet nozzle of the RSV body and support plates and foot
welded to the bottom of the support ring. This support locates the valve
assembly axially.
The foot (15) of the front support is bolted to a base plate (9) secured to
the turbine foundation using retainer plates (11) and stud bolts and nuts
(17). In addition, jacking bolts (14) screwed onto corner plates (welded
to the base plate at two corners) horizontally and on the support foot
(15) vertically locate the front support in position.
Liners (13) are provided between the support feet (15 and 16) and the
base plates (9 and 10) for leveling during installation and to
accommodate relative movement during operation.
MM-M05.02
Rev.001
The rear support (7) is a flexible support which consists of a fabricated

steel structure welded to the Y-piece at the RSV outlet. The vertical
plate of the rear support bracket is provided with a cold spring of 13
mm to accommodate thermal expansion such that the support
becomes vertical during hot condition. The foot (16) of the rear support
is bolted onto the base plate (10) using retainer plates (12) and stud
bolts and nuts (17). This base plate is also located by jacking bolts (14)
similar to the front support.

Mitsubishi
2-31
Chapter 2 General
Reheat Stop Valve

The RSV is of the swing disc type check valve which is held in open
position by its actuator (45) by applying a continuous turning force to
the valve stem (2) to overcome the closing force. The closing force is
applied continuously by the springs (37) in the spring housing (34) and
the torque applied by the weight of the valve disc (4).
The RSV consists of a cast steel body (1) which is bored to hold the
valve stem (2) in position. A support (11) provided at the actuator end
of the valve body and a bearing cover (8) at the opposite end, locate
the valve stem in position. Bushings (14, 15, 16, 17) provided along the
valve stem at four locations reduce friction and enable free movement.
The top of the valve body is provided with an opening and a cover (5) to
enable maintenance on the valve internals. A spiral wound gasket (61)
provides sealing for the flanged top cover joint.
The valve disc (4) is secured to the valve arm (3) by a special nut (55).
The special nut is installed with a small clearance with the valve arm
and it is locked by two knock pins (56) after final adjustment. The valve
arm (3) is secured to the valve stem (2) using four arm keys (6). The
spherical seating surfaces between the valve arm (3) and valve disc (4)
and between the valve arm (3) and special nut (55) are provided with
lapped leak-tight back-seat surfaces to prevent steam leakage.
The outlet bore of the valve body is profiled to match the seating
surface of the valve disc and lapped to form a leak-tight seat.
The RSV actuator (45) is secured to the bottom end of the spring
housing (34) through a flange (46). The valve stem (2) is connected to
the actuator through a lever (27), link (29) and connecting rod (35)
arrangement.
MM-M05.02
Rev.001
The lever (27) is secured to the valve stem (2) by three keys (28). Two
identical links (29) connects the lever (27) and the connecting rod (35)
through linkage pins (30 and 32) and bushings (31 and 33). The
connecting rod is screwed onto the actuator piston rod (66) thus
completing the linkage. This arrangement transforms the linear motion
of the actuator piston rod into angular movement of the valve stem.
The spring housing (34) contains a set of springs (37) which when
compressed by the operation of the actuator provides a continuous
closing torque to the valve stem in the open position. A stopper (39)
installed in the spring housing above the spring seat (38) provides a
mechanical stop within the spring housing and limits the travel of the
RSV actuator in the open direction.

Mitsubishi
2-32
Chapter 2 General
A stopper assembly, mounted on the support (11) adjacent to the lever

(27), provides damping to the lever and actuator in the full open
position. The stopper assembly consists of a set of Belleville washers
(50) installed in a guide (47) and compressed by a stopper rod (48).
The actuator end of the valve body, where the valve stem penetrates,
is provided with a positive sealing arrangement to prevent leakage of
steam along the valve stem. No such sealing arrangement is provided
at the bearing cover end (stem removal end) and steam is allowed to
bleed through the gap between the valve stem (2) and the bushing
(14).
To provide a reliable and maintainable seal at the actuator end, a
spherical seal arrangement is provided on the valve stem. A spherical
shoulder ring (18) installed between a stopper ring (19) (which is a
shrink fit on the valve stem) and the bushing (15) forms a seal tight joint
with the bushing at the actuator end. A spring assembly secured to the
actuator support (11) along the axis of the stem provides continuous
axial force to the stem and ensures a positive sealing joint.
The spring assembly consists of a spring (24), a spring bolt (25), spring
seats (21 and 23), spring compression nuts (26) and a thrust bearing
(22). The spring bolt is screwed onto the valve stem (2) and the spring
(24) provides compressive force when tightened by the compression
nut. The compressed spring provides a continuous axial force to the
valve stem to provide a positive sealing joint between the bushing (15)
and the shoulder ring (18).
The leakage steam at the bearing cover end pressurizes the space
between the trip pilot valve and the valve stem. This pressure build-up
provides an axial thrust on the shoulder ring spherical seating surface
and provides additional force for positive sealing. The trip pilot valve
(20) provided on this leak-off line isolates the leak-off steam at this end
when the RSV is in the open position.
The operational requirement of the RSV is that it stays fully open in

normal service and closes quickly in the event of an emergency
situation. The friction generated by the differential pressure on the
valve stem is therefore of no consequence in normal operation, but the
pressure must be released in an emergency situation to facilitate valve
fast closure. The trip pilot valve performs this function by releasing the
leak-off steam to the main condenser during a RSV closure.
MM-M05.02
Rev.001
Any leakage steam through the bushing (15) at the actuator end is
drained to the gland steam condenser through another stem leak-off
line (68). The intention is to prevent steam pressure build-up at the
actuator end of the stem.

Mitsubishi
2-33
Chapter 2 General
The trip pilot valve has one port connected to the bearing cover and the
other port to the main condenser. The trip pilot valve is kept closed by
the EH HP oil when the turbine is in normal operation. In an emergency
situation, when the EH HP oil pressure is dumped, the trip pilot valve
will open and release the unbalanced steam pressure to the main
condenser.
The RSV is provided with a bypass line to warm-up the RSV/ICV
assembly and to equalize steam pressure between the inlet and outlet
sides of the RSV to reduce valve opening torque. A pneumatically
operated valve installed in the bypass line isolates bypass steam after
the RSV is opened.
A limit switch assembly (67) is mechanically connected to the link (29)
to provide signals for the position indication and operation of the valve.
RSV Actuator Assembly

The RSV actuator is of the single acting device type. The function of
the RSV actuator is to open and close the RSV as required during
turbine operation.
The RSV actuator opens the valve against the spring closing force, the
inlet steam pressure and the torque applied by the weight of the disc.
When hydraulic fluid pressure is applied to the actuator it opens the
valve against these forces. When hydraulic pressure is released from
the actuator, the valve is closed by the spring closing force, self-weight
of the disc and the pressure exerted by the inlet steam.
The RSV actuator mainly consists of a hydraulic cylinder (1), a dump
valve (6), an accumulator (4), a filter (5), an isolation valve, three check
valves and a 3-way solenoid valve (16). The constructional and
functional features of these components except solenoid valve are
similar to those explained for the MSV/GV.
The RSV actuator is provided with a 2 liters capacity accumulator (4)
and it is filled with N2 gas at 0.7 kg/cm2 in the gas side.
MM-M05.02
Rev.001
The RSV actuator is adjusted for 6 mm over-travel to enable the valve

disc to close tightly on the seat.
The RSV actuator is provided with a 3-way solenoid valve (16) which
connects the outlet of the dump valve to the EH drain line. This
solenoid valve is meant for remote controlled testing of the RSV without
affecting other steam admission valves. This facility is provided in
addition to the manual testing performed with the dump valve. The
stem freedom test is to be performed at regular intervals to ensure that
the stem is free and it closes positively during an emergency.

Mitsubishi
2-34
Chapter 2 General
When the solenoid valve is energized or when the EH emergency trip

valve is operated, the EH HP oil between the dump valve and the
check valve (at dump valve outlet) is released to the EH drain line. This
pressure drop operates the dump valve resulting in the closure of the
RSV.
Interceptor Valve
The interceptor valves are of the plug type installed in a vertical position
such that the outlet from the RSV forms the inlet to the ICV. The ICVs
control the outlet steam from the RSV and direct it to the IP element of
the HP-IP cylinder through the outlet loop pipes.
Each ICV mainly consists of a valve body, stem assembly, a bonnet, a
spring assembly, a linkage mechanism and a hydraulic actuator
assembly.
The stem assembly consists of a stem (14), a main valve (2) and a
valve retainer (3). The main valve (2) and the valve retainer (3) are
secured to the valve stem (14). The valve retainer is inserted from the
top of the stem and the main valve is screwed onto the retainer. A
stepped projection at the lower end of the stem retains the main valve
and the retainer from falling. After tightening, the joint between the
main valve and the retainer is peened to prevent loosening. The valve
retainer is installed on the valve stem with a clearance (loose) fit. The
loose fit arrangement provides a limited self alignment capability for the
main valve.
The stem assembly is installed within the valve body (1) and guided by
a stem bushing (15) secured to the bonnet (8).
The main valve (2) is made of a cylindrical piston type disc which
moves within a valve bushing (6) secured to the bonnet. The valve
bushing is retained in the bonnet by four lateral retaining pins (10).
MM-M05.02
Rev.001
The bottom end of the main valve is profiled to match the main valve
seat provided on the valve body. The main valve is provided with two
piston rings (4) around the periphery to prevent leakage of steam
through the main valve. Two rows of piston guides (5), secured to the
outer surface of the main valve, enable smooth movement of the main
valve within the valve bushing. The main valve is provided with three
axially drilled holes to provide equalizing passage between the bottom
and top sides of the main valve.

Mitsubishi
2-35
Chapter 2 General
The bonnet assembly (8) is bolted to the valve body (1) at the top. A
spiral wound gasket (44) installed between the valve body and the
bonnet provides sealing for the flanged joint. The bonnet flange is
provided with jacking bolt (13) to aid during disassembly of the valve. A
lateral passage drilled in the bonnet with matching holes on the stem
bushing provides a stem leak-off path (16).
A spring housing (17) mounted on the bonnet (8) provides support to
the ICV actuator (34) and houses a set of pre-compressed springs (27).
The springs apply a continuous closing force to the stem (14) by virtue
of the spring compression force.
The springs (27) are housed inside the spring housing (17) between
the spring housing cover (45) and the spring seat (28). The cover is
welded to the spring housing at the top. The spring seat is located
within the spring housing and it moves during valve operation.
Three special bolts (32) secured to the cover (45) and three support
plates (29) bolted to the spring seat (28) (at 120 apart) facilitate
compression of springs during maintenance. These support plates
move vertically within three slots provided on the spring housing. The
nuts (33) when tightened release the spring closing force from the
valve stem thus making the valve stem free. The special bolts (32) and
nuts (33) are removed from the spring housing after the final
adjustment of the springs during reassembly.
A cross-head (21) connects the valve stem (14) and the actuator piston
rod (35). The cross-head is screwed onto both the valve steam and the
actuator piston rod and secured by separate lock pins (26 and 36) after
final tightness. A spacer ring (22) and a set of spherical washers (23
and 23a) located between the spring seat and the cross-head provides
limited self alignment capability.
A bracket (39) secured to the cross-head (21) carries an indicator (40)
which moves over a scale (41) secured on the spring housing and
indicates the lift of the valve stem during operation. Linkages to the limit
switch (42) and the LVDT (43) are provided from arm bolts (38)
secured to the cross-head (21).
MM-M05.02
Rev.001
When closed, the combined force exerted by the inlet steam on the
main valve and the closing springs on the valve stem, hold both the
main valve firmly on the valve seat.
High pressure hydraulic oil is supplied to the ICV actuator (34) to open
the valve. This produces a lifting force which overcomes the spring
force holding the main valve in the closed position. As the valve stem
rises, the main valve is lifted from the valve seat and steam is admitted
into the ICV outlet pipe.

Mitsubishi
2-36
Chapter 2 General
The admission of steam into the ICV outlet pipe starts the process of
equalizing steam pressure either side of the main valve. The closing
force on the valve stem is progressively reduced as the steam pressure
equalizes.
As can be seen in Figure 2-17, the area on which the steam pressure
acts to apply force to open the main valve is greater than the area on
which it acts to apply force to close the valve. For this reason, there will
be still a differential pressure across the valve even if the forces acting
on either side of the main valve become equal.
The ICV has a special feature to prevent steam leakage along the valve
stem during its full open position. When the main valve is fully opened,
the valve stem and the stem bushing come into contact to form a
back-seat sealing joint. This back-seat joint prevents steam leakage
through the gap between the valve stem and the stem bushing.
The valve stem (14) is provided with spiral grooves on the periphery at
three locations, where the stem traverses in the main valve retainer (3)
and stepped surfaces in the stem bushing (15), to provide a continuous
leakage of steam along the stem. This leakage steam serves as a
lubricant for free movement of the stem. The stem leak-off pipe (16)
drains the leakage steam to the gland steam condenser.
A strainer (9) secured to the bonnet (8) filters the incoming steam
before entering the IP turbine. This permanent strainer is made from a
16 mm thick stainless steel plate with uniformly drilled 7 mm holes and
is secured to the lip of the bonnet using retaining pins (10). A fine mesh
with 4 mm holes is provided around the permanent steam strainer
temporarily for use during the initial commissioning stages of the
turbine. The purpose of the temporary steam strainer is to screen out
debris from entering the turbine during the preliminary operation period.
Note
Temporary strainer operation should not extend beyond these

recommended limits, as failure of the temporary strainer could cause
severe damage to the IP turbine blading. Also excessive blockage
results in a restricted steam flow passage.
MM-M05.02
Rev.001
The fine mesh temporary steam strainers are not designed for long
life operation and are intentionally susceptible to becoming
clogged with debris during preliminary operation. Therefore, it is
recommended to inspect and remove the temporary strainer
within ninety (90) full days of service. This period is to include
operation for a period of not less than four (4) days with full
volumetric steam flow.

Mitsubishi
2-37
Chapter 2 General
ICV Actuator Assembly

The ICV actuator is of the single acting device type. The spring housing
mounted on the ICV applies a continuous closing force to the valve.
When hydraulic fluid pressure is applied to the actuator it opens the
valve against this spring pressure.
The functional and constructional features of the ICV actuators are
similar to those of the MSV and GV actuators.
The major components of the ICV actuator assembly are similar to
those of the GV. The difference between these two actuators is that no
accumulator is provided for the ICV actuator.
The ICV actuator is provided with a hydraulic cylinder (1), a servo-valve
(7), a dump valve (6), an LVDT, an isolation valve, three check valves,
a filter (5) and a 3-way (OPC) solenoid valve (16). The constructional
and functional features of these components are similar to those
explained for the MSV/GV.
The ICV actuator hydraulic cylinder is adjusted for 6 1 mm over-travel
to enable the main valve to close tightly on the seat.
MM-M05.02
Rev.001
The ICV actuator is also provided with an Overspeed Protection

Control (OPC) solenoid valve (16) similar to the GV to protect the
turbine during overspeeding.

Mitsubishi
2-38
Chapter 2
EQ U A LIZING
VALVE
General
C O VER
TR IP PILO T
VALVE
V ALV E DISC
VALVE
STEM
MM-M05.02
Rev.001
SPR IN G
FIGURE 2-12

Mitsubishi
CUTAWAY VIEW OF THE RSV-ICV ASSEMBLY
2-39
Chapter 2 General
REHEAT STOP VALVE
INTERCEPTOR VALVE
EQUALIZER VALVE
RSV ACTUATOR
ICV ACTUATOR
FRONT SUPPORT
REAR SUPPORT
STIFFENER PLATE
BASE PLATE
10
BASE PLATE
11
RETAINER PLATE
12
RETAINER PLATE
13
LINER
14
JACKING BOLT
15
FOOT
16
FOOT
17
STUD BOLTS & NUTS
STEAM INLET
STEAM OUTLET
4
13
17
12
8
(COLD SPRING)
11
15
16
13
10
13
9
OPERATING FLOOR
16
14
11
12
13
13
17
10
MM-M05.02
Rev.001
14
17
9
15
A-A
MPTD-4-0963
FIGURE 2-13
SUPPORT ARRANGEMENT FOR THE RSV / ICV ASSEMBLY

Mitsubishi
2-40
Chapter 2
11
16 69 13 58 15
27
"D"
19
"H"
12
28
18
14
17
68
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
10
"E"
11
F
OF
AK
70
36
59
31
29
30
32
71
33
36
64
67
29
STEM LEAK OFF
EM
ST
LE
9
57
64
68
63
31
34
62
65
3
42
55
4
34
37
A-A
49
38
41
40
43a 43
20
48
73
47
51
50
46
F
5
56
39
35
53
38
52
61
VALVE BODY
VALVE STEM
VALVE ARM
VALVE DISC
COVER
ARM KEY
COVER STUD AND NUT
BEARING COVER
JACK BOLT
SUPPORT
BEARING SUPPORT
STUD AND NUT
BUSHING
BUSHING
BUSHING
BUSHING
SHOULDER RING
STOPPER RING
TRIP PILOT VALVE
SPRING SEAT
THRUST BEARING
SPRING SEAT
SPRING
SPRING BOLT
NUT
LEVER
LEVER KEY
LINK
LINK PIN
BUSHING
LINK PIN
BUSHING
SPRING HOUSING
CONNECTING ROD
CONNECTING ROD END
SPRING
66 35
39
40
37
SPRING SEAT
STOPPER
SPHERICAL WASHER
RETAINER RING
BOLT, NUT
BOLTS
LONG BOLTS
COMPRESSION BOLT
ACTUATOR
FLANGE
GUIDE
STOPPER ROD
STOPPER NUT
BELLEVILLE WASHER
OUTER SPRING SEAT
INNER SPRING SEAT
SET SCREW
SPACER
SPECIAL NUT
KNOCK PIN
SPHERICAL WASHER
SPIRAL WOUND GASKET
SPIRAL WOUND GASKET
LOCK NUT
SPIRAL WOUND GASKET
LOCK PIN
BUSHING
LINER
EYE BOLT HOLE
ACTUATOR PISTON ROD
LIMIT SWITCH
STEM LEAK-OFF LINE
LINKAGE ROD
LINK
SCALE
SPLIT PIN
15
43 43a
18
3
54
3
34
12
45
DETAIL "D"
24
11
"G"
STEAM INLET
38
39
40
41
42
43
43a
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
General
STEAM
OUTLET
21
22
DETAIL "H"
60
EYE BOLT(M12)
17
25
72
19
EYE BOLT(M24)
41
46
44
20
10
0
10
F-F
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
55
170
180
190
200
B-B
26
MM-M05.02
Rev.001
VIEW C
23
DETAIL "E"
11
56
4
DETAIL "G"
FIGURE 2-14

Mitsubishi
EYEBOLT DETAILS FOR

FOR INSTALLATION OF ARM
SECTIONAL VIEW OF REHEAT STOP VALVE

2-41
Chapter 2 General
TRIP PILOT VALVE
REHEAT STOP
VALVE
TO COND.
STEAM
LIMIT SWITCH
ACCUMULATOR
CHECK
VALVE
HYDRAULIC
CYLINDER
R.S.V. TEST
ISOLATION
VALVE
DUMP VALVE
FILTER
MM-M05.02
Rev.001
EH DRAIN OIL
EH HP OIL
MPTD-4-0965
FIGURE 2-15
PISTON
SCHEMATIC ARRANGEMENT OF REHEAT STOP VALVE ACTUATOR

AND SERVO-SYSTEM

Mitsubishi
2-42
Chapter 2
General
1
2
3
4
5
6
8
9
10
11
12
13
14
15
16
17
18
PART NO.
4 3 2 1
9
5
SERIAL NO.
17
15
11
16
CYLINDER BODY
PIPE BLOCK
VALVE BLOCK
ACCUMULATOR
FILTER
DUMP VALVE
COVER ASSEMBLY
MANIFOLD
HANDLE
TERMINAL BLOCK
PISTON ROD
SEAL CASING
TIE ROD
BOLT
SOLENOID VALVE
FLANGE
'O' RING
8
10
9
4
17
18
3
3
Rev.001
1
12
MM-M05.02
1
14
13
FIGURE 2-16

Mitsubishi
RSV ACTUATOR ASSEMBLY

2-43
Chapter 2
11 12
34
45
18
43
34
37
16
45
45
32
27
29
28
30
31
38
21
19
20
C
L REHEAT STOP VALVE
VIEW E
33
38
11
18
"F"
13
42
35
31
38
42
27
28
17
17
32
35
35
36
21
24
12
VIEW A
23a
8
VIEW C
16
25
34
44
10
23
22
7
14
STEAM INLET
26
41
"G"
4
40
14
21
DETAIL "F"
15
STEAM OUTLET
39
9
3
5
43
3
14
VIEW B
DETAIL "H"
28
23a 23
3+- 02
Rev.001
MM-M05.02
MPTD-3-0967
17
"H"
2
1
22
5
21
38a
VIEW D
DETAIL "G"
FIGURE 2-17

Mitsubishi
General
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
23a
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
38a
39
40
41
42
43
44
45
VALVE BODY
MAIN VALVE
RETAINER
PISTON RING
PISTON GUIDE
VALVE BUSHING
SET PIN
BONNET
STRAINER
RETAINING PIN
STUD BOLT & NUT
SPHERICAL WASHER
JACKING BOLT
STEM
STEM BUSHING
STEM LEAK-OFF PIPE
SPRING HOUSING
LOCATING PIN
SPHERICAL WASHER
CROSS HEAD
SPACER
LINER
DU THRUST WASHER
LOCK PIN
SPRING
SPRING SEAT
SUPPORT PLATE
HEX. BOLT
SOCKET HEAD BOLT
SPECIAL BOLT
NUT
ACTUATOR
ACTUATOR PISTON ROD
LOCK PIN
ARM BOLT
ARM BOLT
BRACKET
INDICATOR
SCALE
LIMIT SWITCH
LVDT
SPIRAL WOUND GASKET
SPRING HOUSING COVER
SECTIONAL VIEW OF INTERCEPTOR VALVE

2-44
Chapter 2 General
INTERCEPTOR VALVE ACTUATOR
HYDRAULIC
CYLINDER
L.V.D.T.
DUMP VALVE
TO DEMODULATOR
FOR OPC
S
LIMIT SWITCH
FILTER
+-20mA
F
FROM SERVO
AMPLIFIER
INTERCEPTOR
VALVE
STEAM
MM-M05.02
Rev.001
MPTD-4-0968
FIGURE 2-18
SCHEMATIC ARRANGEMENT OF ICV ACTUATOR AND

SERVO-SYSTEM

Mitsubishi
2-45
Chapter 2
14
11
1
2
3
5
6
7
8
9
10
11
12
13
14
15
16
18
1 2 3 4 5 6 7 8 9 10 11 12 13
15
7
General
10
16
CYLINDER BODY
PIPE BLOCK
VALVE BLOCK
FILTER
DUMP VALVE
SERVO VALVE
COVER ASSEMBLY
MANIFOLD
HANDLE
TERMINAL BLOCK
PISTON ROD
SEAL CASING
TIE ROD
BOLT
SOLENOID VALVE
'O' RING
3
10
9
3
18
12
9
9
Rev.001
MM-M05.02
14
15
13
1
FIGURE 2-19

Mitsubishi
ICV ACTUATOR ASSEMBLY
2-46
MM-M05.02
Rev.001
Chapter 2 General
FIGURE 2-19a

Mitsubishi
ICV CHARACTERISTIC CURVE
2-47
Chapter 2 General
2.4.3 Steam Admission Valve Control Oil System

The major requirements of the steam admission valves are to open and
control according to the turbine load and to close quickly during an
unsafe turbine condition. The steam admission valves utilize E/H fluid
and HP oil (auto stop oil) for the safe and reliable operation of the main
turbine.
The steam admission valves are operated individually by hydraulic
actuators which are connected suitably to the respective steam
admission valves.
The high pressure oil required for operating the actuators is supplied
from the discharge of the E/H oil pumps during normal turbine
operation.
MM-M05.02
Rev.001
The E/H oil at the discharge of the E/H oil pumps is supplied directly to
the hydraulic cylinders through servo valves for operating the steam
admission valves.

Mitsubishi
2-48
Chapter 2
General
EH DRAIN OIL
FROM AIR PILOT VALVE
#B (FROM FIG.2-21)
PIT
42
DPIT
45
DPI
43
SAMPLING VALVE
EH DRAIN OIL
#C (FROM FIG.2-21)
DPIT
47
POLISHING
FILTER
POLISHING PUMP
OIL
EVACUATION
BACK UP FILTER
RETURN
FILTER
DPIT
46
FULLER'S EARTH
FILTER
AC
M
COOLING WATER
FROM CCCW
DPIT
48
EH OIL COOLER
(A)
PI
46
LEVEL
TRANSMITTER
AIR BREATHER
RELIEF VALVE
150 Mesh.
COOLING WATER
TO CCCW
ACCUMULATOR
LI
41
EH OIL TANK
LEVEL
INDICATOR
TE
31
EH OIL COOLER
(B)
PI
42
EH OIL
PUMP (B)
DPIT
44
F
AC
M
INLINE FILTER
TO EH
OIL TANK
SAMPLING
VALVE
MAKE UP
FLUID
150 Mesh.
PI
41
DPIT
43
EH HP OIL
#A (TO FIG.2-21)
F
AC
M
INLINE FILTER
TO EH OIL TANK
TO EH
OIL TANK
150 Mesh.
EH OIL
PUMP (A)
MM-M05.02
Rev.001
PIT
41
MPTD-3-0970(A)
FIGURE 2-20

Mitsubishi
CONTROL OIL FLOW DIAGRAM FOR STEAM ADMISSION VALVES (1 OF 2)
2-49
Chapter 2
General
LIMIT SWITCH
PIT
31
PS
31
PS
32
PS
33
PS
34
DPIS
35
TRIP PILOT VALVE
REHEAT STOP
VALVE
MAIN STOP VALVE
TO COND.
HP EMERGENCY TRIP OIL

TO ATMOSPHERE
ACCUMULATOR
STEAM
STEAM
MAIN STOP VALVE ACTUATOR
LIMIT SWITCH
S
S
AIR
DEAERATOR
INLET
REHEAT STOP
VALVE ACTUATOR
ACCUMULATOR
TURBINE
OUTLET
NON RETURN VALVE FOR

DEAERATOR EXTRACTION
TO DEMODULATOR
DRAIN
AIR PILOT VALVE

L.V.D.T
HYDRAULIC
CYLINDER
EMERGENCY
TRIP VALVE
DUMP VALVE
S
AUTO STOP
OIL
+- 20mA
FROM SERVO
AMPLIFIER
EH DRAIN OIL
TO EH OIL TANK
R.S.V. TEST
# C (TO FIG 2-20)
DUMP VALVE
GOVERNING VALVE
EH HP OIL
LIMIT SWITCH
# A (FROM FIG 2-20)
ACCUMULATOR
INTERCEPTOR VALVE ACTUATOR
STEAM
HYDRAULIC
CYLINDER
GOVERNING VALVE
ACTUATOR
L.V.D.T
L.V.D.T.
DUMP VALVE
TO DEMODULATOR
TO DEMODULATOR
FOR OPC
FOR OPC
HYDRAULIC
CYLINDER
LIMIT SWITCH
DUMP VALVE
+- 20mA
FROM SERVO
AMPLIFIER
+-20mA
F
FROM SERVO
AMPLIFIER
INTERCEPTOR VALVE
MM-M05.02
Rev.001
STEAM
EH DRAIN OIL
# B (TO FIG 2-20)
MPTD-3-0970
FIGURE 2-21

Mitsubishi
CONTROL OIL FLOW DIAGRAM FOR STEAM ADMISSION VALVES (2 OF 2)
2-47
Chapter 3
Specifications
C h a p t er
3 Specifications
TABLE 3-1
TURBINE STEAM ADMISSION VALVES
MSV/GV Assembly
Main Stop Valve
Governing Valve
Equipment Number
03MAA02AA101, 03MAA02AA102
Type
Double seat plug type (Main/Pilot)
Flow size (diameter)
355.6 mm
Main valve stroke
125 3 mm
Pilot valve stroke
20 1 mm
Design pressure
27.05 MPa
Design temperature
545C
Operating pressure
24.5 MPa
Operating temperature
538C
Weight
5,541 kg
Equipment Number
03MAA03AA101, 03MAA03AA102
03MAA03AA103, 03MAA03AA104
MSV Actuator
Single seat plug type
184 mm
Valve stroke
54 1.5 mm
Design pressure
27.05 MPa
Design temperature
545C
Operating pressure
24.5 MPa
538C
Weight (GV Assembly)
30,045 kg
Cylinder piston diameter
125 mm
Max. Stroke
360 mm
Over travel
6 1 mm
Weight
646 kg
150 mm
Max. Stroke
200 mm
Over travel
6 1 mm
Weight
646 kg
MM-M05.02
Rev.001
GV Actuator
Type

Mitsubishi
3-1
Chapter 3
Specifications
Continued
TABLE 3-1
TURBINE STEAM ADMISSION VALVES
RSV/ICV Assembly
Reheat Stop
Valve
Equipment Number
03MAB02AA101, 03MAB02AA102
Type
Swing check type
635 mm
Design pressure
5.8 MPa
Design temperature
576C
Operating pressure
4.7 MPa
566C
Weight
13,824 kg
Equipment Number
03MAB03AA101, 03MAB03AA102
03MAB03AA103, 03MAB03AA104
Type
Single seat plug type
406 mm
Valve stroke
173 4 mm
Design pressure
5.8 MPa
Design temperature
576C
Operating pressure
4.7 MPa
566C
Weight
7593 / 7599 kg
RSV/ICV
Assembly
Weight
29,736 kg
RSV Actuator
125 mm
Max. Stroke
200 mm
Over travel
6 1 mm
Weight
376 kg
125 mm
Max. Stroke
200 mm
Over travel
6 1 mm
Weight
300 kg
Interceptor Valve
MM-M05.02
Rev.001
ICV Actuator

Mitsubishi
3-2
Chapter 4 Preventive Maintenance
C h a p t er
4 Preventive Maintenance
Preventive maintenance is performed to avoid or minimize the possibility of failure or
deterioration of equipment performance. A constant effort in this regard is required from
maintenance staff to ensure that the unit is available on demand.
There are two categories of preventive maintenance, Routine Maintenance and Annual
Outage Maintenance. Routine maintenance helps to reduce the possibility of outage
and hence the downtime of machinery. Annual outage maintenance is required to
maintain the internal components of the installed equipment.
Though vendor/manufacturers recommendations provide a good basis for the
provision of a preventive maintenance schedule, the frequency and other details should
be updated from time to time based on practical experience and actual feedback
gathered through inspection and normal operation of the equipment/plant.
Consideration of these site related specific issues will make the preventive
maintenance more effective.
4.1
Prerequisites
The necessary prerequisites for the preventive maintenance of the turbine
steam admission valves and servo-systems are as follows:
4.1.1 Scheduling
MM-M05.02
Rev.001
Scheduling is the first activity in the preparation of a preventive

maintenance program, the schedule is to include planning to attend all
operating equipment on a fixed regular basis. Initially, schedules will be
prepared based on vendor/manufacturers generic instructions, the
schedules will, however, be updated (frequency, nature of inspection
etc.) as site specific data becomes available. Preventive maintenance
is to be co-ordinated with other concerned departments. In the case of
a major scheduled outage, maintenance personnel and other
concerned departments are to jointly produce a plan of activities, well in
advance, to decide the inspection activities and other logistics (such as
availability and supply of required equipment, spare parts, tools and
tackle etc.). The schedule is to clearly identify the critical path. Priority
is to be assigned to specific tasks that also involve parallel activities to
reduce the equipment downtime and to complete the work within the
scheduled time.

Mitsubishi
4-1
4.1.2 Department Interface/Notification

Departmental communication is essential and interfacing between
departments is to be maintained to avoid any lack of communication
that may arise and adversely affect routine or annual outage
maintenance work. Prior to commencing preventive maintenance all
concerned persons (shift supervisor, operators etc.) are to be made
aware of the schedule and the nature of the activities that are to take
place. If it becomes clear that there is a problem or conflict of interests
in the schedule (e.g. the maintenance schedule interferes with another
groups work), this is to be resolved by mutual agreement between the
parties involved.
4.1.3 Isolation of Equipment

It is important that isolations are agreed and valid clearances and work
permits are obtained before any maintenance work is performed. The
isolation boundaries of the particular equipment to be taken under
maintenance are to be clearly identified.
In the case of an electrical isolation the power supply shall be
disconnected and/or the fuses removed. In the case of mechanical
isolations, the valves or other mechanical means of isolation, at the
isolation boundaries are to be closed and if possible locked closed. The
system within the isolation boundaries is to be de-pressurized.
4.1.4 Safety Precautions

Before the commencement of any maintenance work, the person in
charge of the work site is to perform a risk assessment and method
statement for the safe execution of the job scope activities, described
within the work permit. Risk assessment includes identifying,
recognizing and understanding the potential hazards associated with
the work. The method statement is to illustrate the safe working
practices in accordance with the safety manual and manufacturers
instruction manual to prevent personal injury and/or equipment
damage.
MM-M05.02
Rev.001
Prior to commencement of actual work the person carrying out the work
is to make a safety check based on the above method statement and
also use his own judgment to ensure that the equipment and the
prevailing working conditions are safe. During maintenance work every
employee should follow the safe working procedures detailed in the
method statement.

Mitsubishi
4-2
4.2
Routine Maintenance
The purpose of routine maintenance is the implementation of the preventive
maintenance program on a day-to-day basis through a planned and correctly
executed inspection. The routine maintenance activities are very important in
that if they are properly carried out, they will enhance equipment reliability. As a
result, good routine maintenance activities may help in cost reduction in the long
run through minimization of equipment downtime.
4.2.1 Preparation
a)
Parts, Tools and Equipment

It is important to prepare the necessary spare parts, tools and
equipment before commencing the actual work. Routine
maintenance generally requires a standard mechanical tool-kit,
consumables, cleaning materials etc. Any shortages of these
items will affect the maintenance activity and may delay the
schedule. Personal Protective Equipment (PPE) is necessary for
maintenance staff at all times.
Upon completion of work, all tools and equipment should be
serviced and stored correctly to ensure availability for further use.
b)
Documentation
Documentation is an important part of any maintenance duty. All
findings should be noted on a comprehensive log sheet, reporting
all aspects of the equipment observed during the routine
inspection. The data recorded in these documents may become
most useful in determining the root cause of equipment failure
found during the routine inspection. Any abnormalities, if
observed, are to be immediately communicated to the concerned
department/personnel for rectification and are to be detailed in
the report.
4.2.2 Inspection and Maintenance

The turbine steam admission valves are to be checked daily for
abnormal noise or vibration and for steam leakage from the valve stem
or body to bonnet joint.
MM-M05.02
Rev.001
The actuators are to be inspected for any leakage of oil, integrity of

linkage pins and actuator supports. The actuator filters are to be
removed, cleaned and reinstalled annually.
Note
It is advisable to change the filters during turbine overhauling.
However, if spare filters are not available, they can be cleaned
by ultrasonic cleaning method. Procedure for the ultrasonic
cleaning of filter is provided in Appendix H.

Mitsubishi
4-3
4.3
Annual Outage Maintenance

The purpose of annual outage maintenance is the implementation of a
preventive maintenance program on a yearly (or some multiple) basis through a
planned and correctly executed maintenance work program accompanying
necessary inspections. Such outage maintenance activities are very important
in the sense that if properly undertaken these enhance the life and reliability of
the equipment.
The turbine manufacturer/vendor has recommended inspection and
maintenance (overhaul) procedures for the turbine steam admission valves and
their servo-systems. These are to be carried out at two and four yearly intervals.
A two year interval is defined by the turbine manufacturer/vendor as a minor
overhaul interval. The turbine major overhaul interval is four years.
The activities are described in Section 4.3.2.
It should be noted that there is a manufacturer recommendation to carry out
Diagnostic Preventive Maintenance (diagnostic investigation for ageing
deterioration) at eight or ten yearly intervals.
The operating authority should refer to the manufacturer/vendor for further
details.
4.3.1 Preparation
a)
Parts Tools and Equipment

Refer to Subsection 4.2.1 a), Parts Tools and Equipment.
In addition, it will be necessary to identify and request the
provision of any spare part requirements.
Annual outage will, in certain cases, require the use of material
handling equipment.
Unused spare parts are to be returned for correct storage and
used spare parts are to be replaced.
b)
Documentation
Refer to Subsection 4.2.1 b), Documentation.
MM-M05.02
Rev.001
Records are to be maintained to record information regarding

spares and consumables used. These records will be used for
future reference and spare parts replacement.
On completion of annual outage maintenance work, the
equipment is to be monitored for correct operation and
maintenance data logging. This will help to determine the correct
intervals of preventive maintenance activities to ensure optimum
plant availability. The correct recording of the findings during
inspection will build a valuable document for future reference.

Mitsubishi
4-4
4.3.2 Inspection and Maintenance

Work is to be carried out in accordance with the manufacturer
recommended inspection and maintenance (overhaul) procedures.
The recommendation for the two year minor overhaul is that the steam
admission valves are dismantled for internal inspection, and that a
performance test of the valves and actuators/servo-systems is carried
out.
The recommendation for the four year major overhaul is that
(additionally) the hydraulic cylinders and servo-systems have selected
parts replaced.
Table 4-1 summarizes the valve inspection and maintenance activities
for the two year minor overhaul. The performance testing is an
operational activity.
The following actuator parts should be replaced during the four year
major overhaul:
Hydraulic cylinder piston rings and oil seals
Servo-valve filter and seals
Solenoid valves
Dump valve, check valve and isolation valve seals.
MM-M05.02
Rev.001

Mitsubishi
4-5
TABLE 4-1
Activity/Check
MSV Components
(Refer to Figure 2-6)
OUTAGE MAINTENANCE CHECKLIST
GV Components
Remarks/Remedial Work
Valve body (1)
Valve body (1)
Valve body (1)
Valve body (1)
Particular intention to
welds, bends and changes
of sections
Visual inspection for:

Localized wear or
polishing
Valve stem (9), Connecting rod

(40) lower,
Valve nut (4)

Valve stem (2)
Lower stem bushing (6),
Upper stem bushing (7)
Bonnet (8)
Flow guide (12)
Bushing (27) and (63),
Connecting rod (22)
Valve stem bushings

(14,15,1,6,17)
Stem (14)
Rectify by lapping,
grinding, or machining
Stem bushing (2)
Main valve bushing (6)
Valve body (1) and bonnet

(8), Main valve (3), Valve
nut (4), Valve stem (2),
Lower stem bushing (6),
Upper stem bushing (7),
LP & HP leak-off flange
(13,14)
Valve body (1), Cover (5),

bearing cover (8) and joint
face with body

Steam cuts, erosion,
indentations, burrs
Intermediate and upper stem

bushings (13,14,15),
Valve body (1) and bonnet (22)

Main valve (3), valve stem (9),
Pilot valve (4)
HP and LP leak off pipe flanges
(28, 59),
Strainer (10),
Valve set (2)
Rev.001
ICV Components

Cracks
General Condition
Main valve bushing (12), Bonnet

bushing (16), spring guide rod
(21), pilot valve nut (5), spring
guide (6)
MM-M05.02
RSV Components
Visual inspection of
keys/keyways/pens/
holes for:
Burrs
Wear,
Miscellaneous
defects
Operating lever linkage pins (49,

51 & 53) and bushings (50, 52)
Stay link pin (47) and bushing
(48)
Main valve to valve nut pin

(5),
Valve stem to special nut
pin (20),
Connecting rod spring guide rod

pin (41) and bushing (42)
Linkage pins (46, 48,

50,52,54), and bushes
(47,49,51,53)
Valve stem to spring guide stem

pin (19)
Connecting rod to knuckle

pin (62)

Mitsubishi
Stem bushing (15)
If defects are noted refer to

supervisor.
Main Valve retainer (3)

Piston ring (4)
Crosshead (21)
Valve disc (4), Arm (3) and

stem (2)
Body (1) and bonnet (8)

Main valve (2)
Valve stem (14)
Valve seat
Shoulder ring (18)
Strainer (9)
Support (11) and Bearing

support (12),. Link (29)
Steam leak-off flange (16)
Valve stem keys (6, 28)
Stem to cross-head pin

(26)
Linkage pins (30,32) and

bushings (31,33)
Actuator piston to
crosshead pin (6)
4-6
Continued from previous page.

TABLE 4-1
Activity/Check
MSV Components
Visual inspection of
fasteners/threads
for:
Upper spring seats/housing bolts

(34,35), Spring housing/bonnet
fasteners (36,38)
Wear
Deformation
Miscellaneous
defects
Retaining screws (17) for upper

stem bushing, Bonnet/body
fasteners (23,25)
Main valve (3)/intermediate stem
bushing (14) threads
Valve stem (9), Spring guide rod
(21) threads
Pilot valve (4)/valve nut (5)
threads
Rev.001
GV Components
RSV Components
Upper spring seat fasteners

(35, 37,39)
Spring housing to bonnet
studs and nuts, (24,25)
Bonnet to body studs and
nuts (9,10)
Main cover fasteners (7)
Valve stem (2) threads,
Special nut (55)
Special nuts (16) threads

Coupling (17) threads
Spring housing fasteners

(42)
Valve nut (4) and main valve

(13) threads
Actuator mounting
fasteners (43, 43a)
Bearing cover fasteners (9)

Support/bearing support to
body fasteners (13)
Disc (4) threads,
Visual inspection for

operating linkage for:
Connecting rod (40)
Operating lever (41)
Lever (27)
Operating lever (44)
Stay link (44)
Link (29)
Wear
Excess clearance
Stay link (54)
Actuator link (45)
Connecting rod (35)
NDE of valve body,

components and
fasteners.
Valve body (1) and bonnet (22)

Main valve (3) and seat (2)
Valve stem (9) and spring guide
rod (21)
Pilot valve (4), valve nut (5),
spring (8) and spring seat (6)
Strainer (10), Connecting rod (40),
Bonnet / body fastener (23, 25),
Spring housing/bonnet fasteners
(36,38),
Upper spring seat bolts (34,35),
Bonnet body gasket fit area,
Valve body (1) (pay attention

to high stress points i.e.
radius/section change)
Valve bonnet (8)
Main valve/valve nut (3,4)
Valve stem (2)
Connecting rod (22)
Valve seat
Bonnet/body studs(9,10)
Spring housing/bonnet
fasteners (24,25)
HP,LP stem leak-off pipe
welds
Body (1)/main cover (5)

joint gasket area
Body (1)/main cover (8)
joint gasket area
For recommended
areas of NDE refer to
Figures 31 and 3-5.
MM-M05.02
OUTAGE MAINTENANCE CHECK LIST
HP, LP steam leak-off pipe welds

Mitsubishi
Main cover studs (7)

Bearing cover studs (9)
Welded areas of bearing
cover (8)
Valve arm (3), Valve disc (4)
Valve stem (2)
Shoulder ring (18)
Valve seat
ICV Components
Remarks/Remedial
Work
Bonnet/body fastener
(11)
Rectify by lapping,
grinding or machining.
Spring housing /bonnet

fastener (19)
If defects are outside

acceptable limit,
components should be
replaced.
Main valve (2)/ valve

retainer (3) threads
Valve stem (14) threads
Cross heads (21)
threads
Not Applicable
Valve body (1), bonnet

(8), and gasket area
Main valve (2) and seat
Main valve retainer (3)
Strainer (9)
Bonnet /body fasteners
(11)
Spring housing/ bonnet
fasteners (19)
Replace small
components unless
defects can be removed
by machining.
It may be to removed
defects, in major
components by grinding
and welding, but please
refer to the
manufacturer.
4-7

TABLE 4-1
Activity/Check
MSV Components
GV Components
RSV Components
ICV Components
Remarks/Remedial
Work
Run out checks
Valve stem (9)
Valve steam (2)
Valve stem (2)
Valve stem (14)
Replace stem shaft and

bushing if run out
exceeds 50% of total
clearance.
Blueing checks on
valve seats, to
confirm that there is
a continuous contact
band around seat
faces, and on
bushing sliding
surfaces.
Main valve (3) to valve seat (2)
Main valve (3) to valve seat.
Disc (4) to seat
Main valve (2) to seat
Pilot valve (4) to main valve (3)
Machining of the contact

surface (followed by lapping)
is acceptable if lapping alone
cannot restore 100% band of
contact.
Shoulder ring (18) to

bushing (15)
Valve stem (14) back

seat inside steam
bushing (15)
Should be 100% band

of contact between
mating surface. Lap
surfaces to achieve
required contact.
(Machining of the contract

surfaces (followed by lapping) is
acceptable if lapping alone cannot
restore 100% band of contact)
Valve stem (9) back-seat on
intermediate stem bushing (14)
(Parts are surface hardened.
Material removal limit (before
replacement) is 0.1/0.2 mm on
stem/bushing respectively).
Intermediate stem bushing (14) to
Upper stem bushing (15)
Upper stem bushing (15) to spring
guide rod (21)
Shoulder ring (18) to

stopper ring (19)
Parts are surfaced

hardened. Material
removal limit (before
replacement) is
0.1mm/0.2 mm of stem
/bushing respectively.
Machining of the
contact surfaces
followed by lapping is
acceptable if the
lapping alone cannot
restore of 100% of band
contact.
Replace the comments

that cannot achieve
continuous contact
band by lapping.
Note also instructions
for individual
components.
Parts are surface hardened.

Material removal limits apply.
MM-M05.02
Rev.001

Mitsubishi
4-8

TABLE 4-1
Activity/Check
Dimensional and
clearance
checks
MSV Components
Pilot valve and spring seat (6) to
stem (9) Axial float : 1.6mm
Pilot valve nut (5) to stem (9) float
(measured with pilot valve nut
tightened): 3.2 0.2 mm.
(To reduce clearance, machine
shoulder of nut. If clearance is too
small, replace components.)
Stem (9) OD / pilot valve nut (5) ID;
Limits : 1.45 -1.75mm
Stem (9) ID to spring seat (6) OD
Limits: 0.3 - 0.4mm
Stem (9) OD/lower stem bushing
(13) ID; Limits: 0.4-0.5mm
Stem (9) OD/intermediate stem
bushing (14)ID; Limits: 0.4 0.5mm
Stem (11) OD/ upper stem bushing
(15) Limits: 0.4 0.5mm
Lower stem bushing (13) OD/ Main
valve (3) ID Limits; 0.050.14
MM-M05.02
Rev.001
Main valve (3) OD/ main valve

bushing (12) ID Clearance;
Limits: 0.55-0.65mm.
Spring guide rod (21) OD/ bonnet
bushing (16) ID; Limits:
0.25-0.35mm
Linkage pin (47) OD/ Bushing (48)
ID, Limits: 0.05-0.25mm

Mitsubishi
GV Components
RSV Components
ICV Components
Remarks/Remedial
Work
Valve stem (2) thermal

expansion clearanceLimit:
0.7-0.8mm
Clearance between stem

OD and bushing (14) ID
Limits: 0.46-.053mm
To reduce clearance, machine

valve nut (4) seating at the
valve (3).

OD and bushing (15,26)
ID Limits: 0.45-0.55mm
Valve stem (14) OD and

stem bushing (15) ID (Top
clearance): Limit:
0.27-0.36mm
During overhaul
restore clearances to
the values shown, by
machining or the
replacement of parts.
If clearance is too small replace

valve or nut is necessary.

OD and bushing (17) ID;
Limits: 0.38-0.48mm
Clearance between valve stem

(2) OD and lower stem bushing
(6) ID, Limit: 0.4-0.45mm
(2) OD and upper stem bushing
(7) ID, Limit: 0.4-0.45mm
Clearance between valve nut
(4) OD/ flow guide (12) ID, Limit:
0.405-0.46mm
Clearance between valve nut
(4) lip OD/ Flow guide (12) lip ID
Limit: 2.38-3.62mm
Clearance between connecting
rod (22) OD and bushing (27) ID
Limit: 0.25-0.35mm
(2) OD and special nut (16) ID;
Limits: 0.10-0.15mm
rod (22) ID and special nut (16)
OD; Limits: 0.012-0.069mm
Axial clearance between

arm (3) and bushing (14)
Limit: 2.0mm
(2) OD and arm (3) ID
Limit: 0.4-0.5mm
Clearance between arm
(3) OD and special nut
(55) Limit: 0.33-0.38mm
(Nut is adjustable and
holes for pins (56) can be
re-drilled.
Clearance between arm
(3) OD and special nut
(55)
Limit: 3.0-3.2mm
Clearance between
connecting rod (35) OD
and bushing (63) ID
Limits: 0.75-0.15mm
Valve stem (14) OD to stem

bushing (15) ID bottom
clearance;
Limit:0.41-0.50mm
Valve stem (14) OD to
Crosshead (21) ID
Limit: 0.02-0.105mm
Actuator piston rod (35) OD
to cross-head (21) ID
Limit: 0.2-0.3mm
Clearances shown in
this table are design
clearances to be
achieved when parts
are replaced.
Maximum wear in
bushings 1.5 / Design
clearance as shown
in Figure 4-6 to 4-9.
Main valve (2) OD to main

valve bushing (6) ID
Limits: 1.19-1.35mm
Piston ring (4) to main valve
(2) axial clearance
Limit: 6.35-6.6mm
Piston ring joint gap:
Limits: 6.35-6.6mm
Expansion clearance of
stem end and valve retainer
(3): 3.6 0.2mm
(To reduce clearance,
machine valve retainer. If
clearance is to small
replace valve retainers)
4-9

TABLE 4-1
Activity/Check
Dimensional and
clearance
checks
MSV Components
GV Components
Linkage pin (49) OD/ Bushing (50)

ID and Operating level (54) ID ;
Limits: 0.05 0.25mm
Linkage pin (46) OD/ Bushing

(47) ID;
Limits: 0.036 0.106mm
Linkage pin (51) OD / Bushing (52)

ID and Operating lever (44) ID;
Limits: 0.05 0.25mm

(49) ID and Operating lever (41)
ID Limits: 0.036 0.106mm
Linkage pin (53) OD / Bushing (67)

ID and operating lever (44) ID;
Limits: 0.05 0.25mm

(51) ID; Limits: 0.096
0.266mm
Depth of gasket recesses in the

valve body and bonnet. (Combined
recess should be less than gasket
thickness.
Linkage pin (50) OD / Bushing

(51) ID; Limits: 0.096-0.266mm
(59) ID; Limits: 0.046-0.116mm
(53) ID; Limits: 0.09-0.25mm
Linkage pin (52) OD/ Lever pin
(41) ID; Limits: 0.03-0.09mm
Linkage pin (54) OD / Link (45)
ID; Limits: 0.03 0.09mm
rod (22) OD and upper spring
seat bushing (63) ID
Limits: 0.25-0.35mm
RSV Components
ICV Components
Remarks/Remedial
Work
Clearance between
linkage pin (30) OD and
bushing (31) ID;
Limits: 0.08 0.22mm
Clearance between
lever (27) ID:
Limits: 0.05-0.12mm
Clearance between
bushing (33) ID
Limits: 0.08-0.22mm
Clearance between
rod end (36) ID;
Limits: 0.05-0.12mm
Depth of gasket recesses
in the valve body and all
covers. (Combined
recesses should always
be less than gasket
thickness.
Rev.001
Depth of gasket recesses in the

valve body and bonnet.
MM-M05.02
(Combined recess should be

less than gasket thickness.

Mitsubishi
4-10
LIQUID PENETRANT EXAMINATION FOR MAIN STOP VALVE
21
22
10
25
35
40
38
23
36
A
34
59
10
28
MM-M05.02
Rev.001
C- C
1
2
3
4
5
6
9
10
21
22
23, 25
28
34
35
36, 38
40
59
A
STEAM CHEST
VALVE SEAT
MAIN VALVE
PILOT VALVE
PILOT VALVE NUT
SPRING SEAT
VALVE STEM
STRAINER
SPRING GUIDE ROD
BONNET
BONNET BOLT & NUT
STUD BOLT, NUT
LONG BOLT
SPRING HOUSING FASTENERS
CONNECTING ROD
GASKET AREA
MPTD-4-0971
FIGURE 4-1

Mitsubishi
MAIN STOP VALVE NDT AREAS
4-11
LIQUID PENETRANT EXAMINATION FOR GOVERNING VALVE
1
2
3
4
8
9
10
13
14
22
24
25
A
B
22
10
25
24
STEAM CHEST
VALVE STEM
MAIN VALVE
VALVE NUT
BONNET
STUD BOLT
NUT
CONNECTING ROD
STUD BOLT
NUT
GASKET AREA
SEAT AREA
13
8
14
A
2
4
3
MM-M05.02
Rev.001
MPTD-4-0972
FIGURE 4-2

Mitsubishi
GOVERNING VALVE NDT AREAS

4-12
LIQUID PENETRANT EXAMINATION FOR REHEAT STOP VALVE
18
"H"
5
8
3
4
B
18
1
2
3
4
5
7
8
2
DETAIL "H"
9
18
A
B
MM-M05.02
Rev.001
STEAM INLET
VALVE BODY
VALVE STEM
VALVE ARM
VALVE DISC
COVER
COVER STUD AND NUT
BEARING COVER
BEARING COVER
STUD AND NUT
SHOULDER RING
GASKET AREA
SEAT AREA
STEAM
OUTLET
B-B
MPTD-4-0973
FIGURE 4-3

Mitsubishi
REHEAT STOP VALVE NDT AREAS

4-13
LIQUID PENETRANT EXAMINATION FOR INTERCEPTOR VALVE
1
2
3
8
9
11
19
A
B
VALVE BODY
MAIN VALVE
RETAINER
BONNET
STRAINER
BONNET STUD & NUT
SPRING HOUSING BOLT
GASKET AREA
SEAT AREA
19
11
8
A
9
2
3
MM-M05.02
Rev.001
B
1
MPTD-4-0974
FIGURE 4-4

Mitsubishi
INTERCEPTOR VALVE NDT AREAS
4-14
UT/MT
UT/MT
UT/MT
UT/MT
UT/MT
MAIN STOP VALVE
GOVERNING VALVE
UT/MT
UT/MT
UT/MT
UT/MT
REHEAT STOP VALVE
NOTE: THE MANUFACTURER RECOMMENDS BOTH

ULTRASONIC AND MAGNETIC PARTICLE TEST
ON THE NUTS AND SPHERICAL WASHERS
DURING MAJOR OVERHAULS.
Rev.001
MM-M05.02
INTERCEPTOR VALVE
UT- ULTRASONIC TEST

MT- MAGNETIC PARTICLE TEST
MPTD-4-0975
FIGURE 4-5

Mitsubishi
NDT ON COVER JOINT NUTS AND SPHERICAL WASHERS
4-15
Chapter 4
3.2 +- 0.2
LAP SURFACES
0.05~0.25 (ON DIA.)
50
1.45~1.75ON DIA.)
0.3~0.4 (ON DIA.)
LAP SURFACES
49
0.05~0.25 (ON DIA.)
B
44
1.6
C
52
51
B
2
"D"
10
1
67
53
0.05~0.25 (ON DIA.)
0.23~0.53(ON DIA.)
A-A
11
0.4~0.5 (ON DIA.)

21
20 +- 1
PILOT VALVE
TRAVEL
0.05~0.14 (ON DIA.)
16
27
22
22
0.4~0.5 (ON DIA.)
0.1~0.15 (ON DIA.)
MM-M05.02
Rev.001
0.25~0.35 (ON DIA.)

9
13
15
125 +- 1
MAIN VALVE
TRAVEL
14
12
0.55~0.65 (ON DIA.)
1
2
3
9
12
13
14
15
16
21
22
44
49
50
51
52
53
67
STEAM CHEST
VALVE SEAT
MAIN VALVE
VALVE STEM
MAIN VALVE BUSHING
LOWER STEM BUSHING
UPPER STEM BUSHING
BONNET BUSHING
SPRING GUIDE ROD
BONNET
OPERATING LEVER
LINKAGE PIN
DU BUSHING
LINKAGE PIN
DU BUSHING
LINKAGE PIN
DU BUSHING
MPTD-3-0976
FIGURE 4-6

Mitsubishi
MAIN STOP VALVE CLEARANCE DRAWING
4-16
Chapter 4
0.096~0.266(ON DIA.)
0.09~0.250(ON DIA.)
1
2
3
4
6
7
8
13
16
17
22
23
31
45
48
49
50
51
52
53
54
59
60
63
68
STEAM CHEST
VALVE STEM
MAIN VALVE
VALVE NUT
LOWER STEM BUSHING
UPPER STEM BUSHING
BONNET
FLOW GUIDE
SPECIAL NUT
COUPLING
CONNECTING ROD
SPRING HOUSING
UPPER SPRING SEAT
ACTUATOR LINK
LINKAGE PIN
DU BUSHING
LINKAGE PIN
DU BUSHING
LINKAGE PIN
DU BUSHING
LINKAGE PIN
BUSHING
GASKET
BUSHING
BUSHING
50
C
B
B
0.036~0.106(ON DIA.)
59
49
52
48
45
0.046~0.116(ON DIA.)
51
B-B
0.2~0.26 (ON DIA.)
0.09~0.25(ON DIA.)
22
53
52
0.03~0.09(ON DIA.)
0.03~0.09(ON DIA.)
0.03~0.09(ON DIA.)
0.03~0.09(ON DIA.)
31
63
0.05~0.15 (ON DIA.)
68
0.1~0.2 (ON DIA.)
54
0.4~0.45 (ON DIA.)
0.09~0.25(ON DIA.)
60
8
23
0.3~0.5 (ON DIA.)
C-C
8
22
54 +- 1
TRAVEL
2
0.012~0.069 (ON DIA.)
0.25~0.35 (ON DIA.)
17
12
0.405~0.46 (ON DIA.)
16
2.38~3.62 (ON DIA.)
MM-M05.02
Rev.001
0.1~0.15 (ON DIA.)
0.4~0.45 (ON DIA.)
0.7~0.8 (CLEARANCE)
3
MPTD-3-0977
FIGURE 4-7

Mitsubishi
GOVERNING VALVE CLEARANCE DRAWING
4-17
Chapter 4
0.08~0.22 (ON DIA)
0.08~0.22 (ON DIA)
11
1
3
6
8
11
12
14
15
16
17
27
29
30
31
32
33
34
35
59
63
16
27
0.45~0.55 (ON DIA)
0.38~0.48 (ON DIA)
17
30
31
29
12
15
VALVE BODY
VALVE ARM
ARM KEY
BEARING COVER
SUPPORT
BEARING SUPPORT
BUSHING
BUSHING
BUSHING
BUSHING
LEVER
LINK
LINK PIN
BUSHING
LINK PIN
BUSHING
SPRING HOUSING
CONNECTING ROD
SPIRAL WOUND GASKET
BUSHING
0.05~0.12 (ON DIA)

3.0~3.2 (ON DIA)
32
0.08~0.22 (ON DIA)
29
0.08~0.22 (ON DIA)
0.33~0.38 (ON DIA)

0.40~0.50 (ON DIA)
0.04~0.12 (ON DIA)
0.46~0.53 (ON DIA)
0.05~0.12 (ON DIA)
33
63
34
2
Rev.001
35
MM-M05.02
0.075~0.15 (ON DIA)
0.2~0.25
FIGURE 4-8

Mitsubishi
14
59
REHEAT STOP VALVE CLEARANCE DRAWING
4-18
Chapter 4
35
0.2~0.3 (ON DIA)
14
173+4
21
0.27~0.36 (ON DIA)
0.02~0.105 (ON DIA)
14
17
15
8
2
3
4
5
6
8
14
15
17
21
35
0.41~0.50 (ON DIA)
MAIN VALVE
RETAINER
PISTON RING
PISTON GUIDE
VALVE BUSHING
BONNET
STEM
STEM BUSHING
SPRING HOUSING
CROSS HEAD
ACTUATOR
PISTON ROD
0.05~0.15 (ON DIA)
6
14
3.6 +
- 0.2
6.35~6.6
0.5~0.6
2
8
6.35~6.6
MM-M05.02
Rev.001
3
1.19~1.35(ON DIA)
VIEW A
MPTD-3-0979
FIGURE 4-9

Mitsubishi
INTERCEPTOR STOP VALVE CLEARANCE DRAWING
4-19
Chapter 5
C h a p t er
5 Disassembly and Reassembly

Disassembly and reassembly are the activities to be conducted when internal parts of
the equipment are required to be accessed. An important part of the activities is the
preparatory work. This should identify the manpower, spares and tools that may be
required during the maintenance work. A shortfall of any of these may affect the preset
schedule and the operational status of the plant. The major steps associated with
disassembly and reassembly are as follows.
5.1
Disassembly and Reassembly of Main Stop Valve
CAUTION
Prior to carrying out any maintenance, confirm all isolations are
in place and the equipment is shut down.
a)
Preparation
MM-M05.02
Rev.001
If disassembly of a MSV becomes necessary, all associated equipment

shall be mechanically and electrically isolated and an authorized
clearance and work permit shall be in place prior to the commencement of
work. The following points are also to be considered when preparing for
disassembly and reassembly.
Have all necessary drawings (assembly drawings etc) and documents

(log sheets, field record book, etc) ready prior to start of work.
Prepare the necessary handling facilities (e.g. crane facilities,

temporary supports, etc) to remove and store the various parts of the
equipment.
When lifting heavy equipment, use a crane, chain block, or other

appropriate lifting equipment. Also ensure that the safe working load
(SWL) of wire slings, shackles, eyebolts and lifting gear being used is
adequate for the load being lifted.
When using a crane, chain block, etc, the center of gravity of the item
being lifted should be considered and the lift should be well balanced
and level.
Special tools are listed in Appendix C.

Mitsubishi
5-1
Chapter 5
b)
Disassembly
Before starting disassembly, prepare a lay-down area where equipment
can be stored and worked on without undue risk of contamination or
damage.
Tag all components for identification purposes. If necessary bag or wrap
to prevent miscellaneous losses and ensure adequate protection.
Wear protective clothing, respiratory equipment and goggles

when handling insulation.
CAUTION
When separating joints and flanges use jacking bolts and
wooden mallets. Never apply force with hammers, chisels or
screwdrivers.
All data is to be recorded during disassembly. During disassembly make

match marks on adjoining parts for ease of identification during
reassembly.
1
Before disassembly, the as found closed end over travel of the

actuator hydraulic cylinder should be measured and recorded. The
procedure is as follows:
(i)
Ensure that the valve is fully closed. Note the position of the
actuator piston rod indicated by the indicator on the scale (66)
secured to the actuator (62).
MM-M05.02
Rev.001
(ii) Disconnect the actuator from the valve by removing the split pins,
washers and the linkage pin (53) at the operating lever (44).
Remove the linkage and disconnect the LVDT (57) from the
piston rod.
(iii) Fully close the hydraulic cylinder at this valve disconnected
condition. Note the new position of the actuator piston rod
indicated on the scale (66).
(iv) Record the difference in the readings in Steps (i) and (iii) between
the fully closed positions at the valve connected and
disconnected conditions as the closed end over travel.

Mitsubishi
5-2
Chapter 5
Disconnect and tag all I&C equipment in the vicinity of the MSV and
the MSV actuator subject to maintenance.
Disconnect the hydraulic oil lines to the actuator and install protective
covers or plugs.
Rig the actuator (62) and remove the actuator support fasteners (64).
Remove the actuator from the actuator support and transport it to the
lay-down area.
Remove cladding and lagging as necessary to expose the valve

bonnet flange and the leak-off (flange) connections.
Unbolt the HP and LP leak-off connections (28 and 59).
Remove the securing fasteners and then remove the limit switch link
(56) from the operating lever (44).
Install and tighten the spring compression bolts (39) to release the
spring compression from the connecting rod (40).
Provide temporary supports to the operating lever and the stay link
(54). Remove the split pin and the linkage pin (49) and disconnect the
operating lever and the stay link. Remove the bushing (50) from the
operating lever if essential.
10 Remove the split pins and the linkage pin (47) and remove the stay
link (54) from the lug secured to the spring housing (29). Remove the
bushing (48) from the stay link if necessary.
11 Rig and support the operating lever (44) for removal. Remove the split
pin from the linkage pin (51) and disconnect the operating lever (44)
and the connecting rod (40). Lift and remove the operating lever to the
lay-down area. Remove the bushing (50) from the operating lever if
necessary.
12 Remove the securing bolts and then remove the supports (61) with
the guide plate (60). Remove the guide plate from the support if
replacement or repair is necessary.
MM-M05.02
Rev.001
13 Loosen and remove the nuts from the stud bolts (34) at the upper
spring seat (30). Slowly loosen the long bolts (35) until the spring
tension is completely released. Remove the long bolts (35) after the
spring tension has been completely released.
Do not loosen the long bolts from the spring housing until the
stud nuts are removed. Remove the long bolts only after
releasing complete tension from the springs. Spring pressure
could force the cover off and injure personnel in the vicinity of
the work.

Mitsubishi
5-3
Chapter 5
14 Rig and remove the upper spring seat (30), the compression springs
(33) and the lower spring seat (31) from the spring housing (29) using
the overhead crane. Transport the removed components to the
lay-down area.
Note
Suitably support the connecting rod (40) while removing the
above components.
15 Release and remove the nuts (38) which secure the spring housing to
the valve bonnet (22). Remove the spherical washers (37) from the
stud bolts (36).
16 Rig and remove the spring housing horizontally using the crane and
transport it to the lay-down area.
17 Hold the connecting rod suitably and remove the split pins (43) and
the pin (41) from the connecting rod/spring guide rod joint. Remove
the connecting rod (40) and transport it to the lay down area. Recover
the bushing (42) between the connection rod (40) and the spring
guide rod (21).
18 Remove the spring guide (32) from the spring guide rod (21).
Note
Before disassembly of the MSV internal parts, it will be necessary
to measure the as found pilot valve travel and main valve travel.
19 The procedure for measuring the as found pilot valve travel is as

follows:
(i)
Place a bar through the linkage pin hole in the valve spring guide
rod (21).
(ii) Using this bar lift the spring guide rod (21) and valve stem (9)
assembly until the shoulder on the stem makes contact with the
back seat inside the intermediate stem bushing (14). Take care
not to lift the main valve from its seat. Measure the distance from
a suitable reference point on the spring guide rod to the upper
surface of the bonnet bushing (16).
MM-M05.02
Rev.001
(iii) Lower the spring guide rod and valve stem assembly until the
pilot valve (4) is seated properly.
(iv) Apply a force (minimum 20 kg) to the bar to firmly close the pilot
valve. Measure the distance from the spring guide rod reference
point to the upper surface of the bonnet bushing (16) as
performed in Step (ii).

Mitsubishi
5-4
Chapter 5
(v) The difference between the measurements noted in Steps (ii) and
(iv) minus the thermal expansion clearance (1.6 mm) is the pilot
valve travel. Record this value.
20 The procedure for measuring the as found main valve travel is as
follows:
(i)
Lift the valve stem with the bar through the spring guide rod (21).
Continue lifting until the intermediate stem bushing (14) contacts
the back seat at the upper stem bushing (15). Measure the
distance from the reference point on the spring guide rod to the
bonnet bushing (16).
(ii) The difference between the measurements noted in Steps 19-(ii)

and 20-(i) is the main valve travel. Record this value.
Bolt heaters are electrical devices capable of causing personnel

injury or death if improperly used.
21 Heat and stretch the stud bolts (23) in accordance with the
instructions in Appendix F. Release and remove the cap nuts (25)
from the stud bolts and then remove the spherical washers (24).
22 Rig the bonnet (22) for removal and using the crane carefully take up
the slack in the rigging.
Note
Given the orientation of these valves, it will be necessary to
consider the lifting and handling carefully and in advance of the
work being carried out. Ensure that the personnel who are to
carry out the work are sufficiently experienced.
23 Using the three jack bolts (65) provided, separate the joint between
the bonnet and the steam chest. Remove the bonnet and valve
internals from the steam chest as a single assembly and transport it to
the lay-down area. If necessary, adjust or apply additional rigging as
the assembly is withdrawn horizontally from the steam chest. Remove
and discard the spiral wound gasket (27) from the steam chest.
MM-M05.02
Rev.001
CAUTION
Lack of preparation and care during the removal of the bonnet
and valve internals can cause damage to the valve or stem. If
necessary, adjust rigging to ensure that the valve is not
damaged during removal of the bonnet and valve internals.

Mitsubishi
5-5
Chapter 5
24 Install a temporary cover over the opening to prevent foreign

materials or debris from entering the steam chest.
25 Provide temporary supports and install the bonnet assembly vertically.
Lift the spring guide rod (21) to expose the pin (19), then tap and
remove the pin (19) which connects the spring guide rod to the valve
stem. Refer to Detail D in Figure 2-6.
Note
Provide support to the valve stem assembly at the bottom while
removing the pin (19) to avoid falling.
26 Insert a suitable bar into the slot in the valve stem through the
horizontal port in the main valve and lock the valve stem as shown in
Figure 5-2. Unscrew and remove the spring guide rod out of the
bonnet bushing (16). Then withdraw the valve stem assembly from
the steam chest side of the bonnet.
27 Holding the main valve at the bottom, unscrew and remove the
intermediate stem bushing (14) and lower stem bushing (13) as a
single assembly. Note that there is a special tool (box spanner)
identified in Appendix C for this activity.
28 Remove the lock pin (63) and then unscrew and separate the
intermediate stem bushing and the lower stem bushing, if required.
29 Remove the valve stem (with pilot valve) assembly from the main
valve (3).
30 Unscrew the pilot valve nut (5) and remove the pilot valve (4) from the
valve stem. Note that there is a special tool identified in Appendix C
for this activity.
31 Remove the pilot valve spring seat (6) and spring (8) from the bottom
end of the valve stem. Recover the shims (7) between the spring seat
and the spring. Measure and record the shim thicknesses.
32 Unscrew and remove the upper stem bushing (15) from the bonnet if
inspection and/or replacement are required.
33 Remove the securing bolts (17) and then remove the bonnet bushing
(16) if inspection and/or replacement are essential.
MM-M05.02
Rev.001
34 Remove the main valve bushing (12) from the bonnet if replacement
is essential.
Note
The main valve bushing is secured to the bonnet by shrink
fitting and peening.

Mitsubishi
5-6
Chapter 5
c)
Reassembly
The reassembly procedure is carried out in the reverse sequence to that
for disassembly. Install all parts in the same positions they were removed
from, referring to the match marks and checking that the clearances are
maintained as specified in Chapter 4.
All contact surfaces are to be cleaned before starting reassembly and all
gaskets are to be replaced with new.
1
During reassembly, lubricate all bolts and studs with N-5000.
Install the plug (18) into the top end of the valve stem (9) (if removed
during disassembly) and tighten it to the torque value specified in
Appendix A.
Install the pilot valve spring (8) into the bottom end of the valve stem
(9) and ensure that it is properly seated.
Install the shims (7) in their original location on the pilot valve spring
seat (6) removed during disassembly.
Insert the pilot valve spring seat (with shims) into the valve stem (9).
Install the pilot valve (4) onto the pilot valve spring seat (6) and ensure
that both the components engage properly.
After assembling the valve stem components, slide the pilot valve nut
(5) from the top end of the valve stem. Hold the pilot valve suitably
and screw the pilot valve nut into the pilot valve.
Note
Tighten the pilot valve nut to the pilot valve using the specific tool
(special spanner) identified for this activity. Peen and lock the pilot
valve nut after full tightness at four locations to prevent it from
loosening during operation.
Screw and tighten the lower stem bushing (13) onto the intermediate
stem bushing (14) and lock them by the lock pin (63).
Rev.001
Slide this intermediate stem bushing and lower stem bushing

assembly onto the valve stem (9) from the top end as far as it will go.
MM-M05.02
While performing Steps 5~6, set 1.6 mm thermal expansion

clearance between the valve stem and spring seat and obtain
spring compression of 11.30.36 mm either by adjusting the
shims (7) or by machining the spring seat (6).
10 Install the pilot valve/stem assembly (assembled in Steps 2 ~ 9) into

the main valve (3).

Mitsubishi
5-7
Chapter 5
11 Screw the intermediate/lower stem bushing assembly into the main

valve (3). Note that there is a specific tool (box spanner) and a main
valve support identified for tightening the intermediate stem bushing.
Lock the intermediate stem bushing to the main valve after full
tightness by peening to prevent it from loosening.
12 Install and tighten the upper stem bushing (15) into the bonnet (22)
from the steam chest side. Secure the bushing to the bonnet by
peening.
13 Install the main valve bushing (12) into the bonnet (21) and secure it
to the bonnet by peening.
Note
The main valve bushing is installed on the bonnet by shrink
fitting.
14 Install the bonnet bushing (16) into the bonnet (22) from the spring
housing side and secure it to the bonnet using the retaining bolts (17).
15 Carefully install the valve stem (with main valve) assembly into the
bonnet from the steam chest side. The parts should slide together
easily without binding or the need to use excessive force. Any
problem should be investigated and resolved before continuing.
16 When the valve stem exits through the upper side of the bonnet,
insert the lock bar through the main valve horizontal port (used during
disassembly) and engage it with the slot in the valve stem to lock the
valve stem as shown in Figure 5-2.
17 Screw and tighten the spring guide rod (21) onto the valve stem (9) to
the torque value specified in Appendix A.
18 Remove the inserted lock bar and lift the valve stem/spring guide rod
assembly through the bonnet bushing (16) until the pin (19) can be
inserted. Ensure that the pin doesnt protrude through the valve stem
at both ends. Lock the pin (19) by caulking at both ends.
19 Ensure that the bonnet stud bolts (23) are correctly fitted into the
steam chest.
MM-M05.02
Rev.001
20 Place a new gasket (27) into the recess in the steam chest.
21 Remove the temporary cover and perform a final inspection of the
interior of the steam chest. Remove any foreign materials or debris
that may have entered.
22 Rig the bonnet and stem assembly and transfer it to the work area in
preparation for replacement.

Mitsubishi
5-8
Chapter 5
23 Align the bonnet and stem assembly with the steam chest. Verify that
the faces are parallel to within 0.03 ~ 0.23 mm while sliding the
bonnet and valve internals into the steam chest. Perform an initial pull
down with four nuts.
CAUTION
Improper alignment of the bonnet and valve internals can cause
damage to the valve stem and main valve. If necessary, adjust
rigging to ensure that the valve is not damaged during
replacement of the bonnet and valve internals.
24 Install the spherical washers (24) and nuts (25) onto the bonnet stud
bolts.
25 To close the joint, tighten the nuts in an alternating (side to side)
pattern to compress the gasket. Ensure that the bonnet and steam
chest faces are parallel to within 0.5 mm as the joint is tightened.

26 Heat the stud bolts (23) using bolt heaters in accordance with the
instructions provided in Appendix F. Perform the final tightening of the
nuts to the torque/bolt-stretch values specified in Appendix A.
27 Remove the bolt heaters from the stud bolt nuts after final tightening.
28 Before reassembly of the operating mechanism, it will be necessary
to measure the travel for the pilot valve and the main valve. Repeat
the procedure given Steps 19 and 20 in the disassembly section.
MM-M05.02
Rev.001
The designed value for pilot valve travel is 20 1 mm. If the pilot valve
travel is outside these tolerances, the valve should be disassembled
to correct the travel. Adjust the pilot valve travel by machining the
shoulder in the intermediate stem bushing.
The designed value for main valve travel is 125 1 mm. If the main
valve travel is outside these tolerances, the valve should be
disassembled to correct the travel. Correct the main valve travel by
machining either the intermediate stem bushing or the upper stem
bushing.
29 Install the spring guide (32) onto the spring guide rod (21) and ensure
that it seats properly on the mating surface.

Mitsubishi
5-9
Chapter 5
30 Replace and secure the connecting rod (40) to the spring guide rod
(21) using the bushing (42), linkage pin (41) and split pin (43).
31 Rig the spring housing (29) and transfer it to the work area. Holding
the connecting bar (40) suitably in the horizontal position, carefully
install the spring housing onto the valve bonnet. Perform an initial pull
down with four nuts.
32 Install the spherical washers (37) and nuts (38) onto the stud bolts
(36).
33 Tighten the nuts and stretch the stud bolts in accordance with the
procedure in accordance with Appendix F to the torque value
specified in Appendix A.
34 Install the lower spring seat (31) and the springs (33) into the spring
housing (29).
35 Position the upper spring seat (30) and install the spherical washers
and the long bolts (35).
36 Progressively compress the springs by tightening the long bolts (35)
in an alternating pattern.
37 When the upper spring seat is seated firmly on the spring housing,
install the spring washers and nuts onto the stud bolts (34) and
tighten the nuts.
38 After installing the upper spring seat, tighten the spring compression
bolts (39) until the valve stem is free from the spring closing force.
39 Install the guide plate (60) and the guide plate supports (61) onto the
upper spring seat (30). Ensure that the connecting rod slides
smoothly on the guide plate.
40 Connect the stay link (54) to the spring housing (29) and replace the
linkage pin (47) and the bushing (48) and secure the linkage pin with
a split pin.
41 Replace the bushing (52) and the linkage pin (51) and secure the
operating lever (44) to the connecting rod (40). Secure the linkage pin
with split pins.
MM-M05.02
Rev.001
42 Connect the stay link (54) to the operating lever (44) and replace the
linkage pin (49) and the bushing (50). Secure the linkage pin with split
pins.
43 Reconnect the HP and LP leak-off pipework (28 and 59).
44 Replace the lagging and cladding removed during disassembly.

Mitsubishi
5-10
Chapter 5
45 Rig the actuator assembly (62), lift it into the position on the valve
from where it was removed and replace the mounting fasteners.
46 Install the linkage pin (53) connecting the operating lever to the
actuator and secure it with split pin.
47 Replace the limit switch assembly (55) onto the upper spring seat and
connect it to the operating lever with the linkage (56).
48 Replace the linkage (58) and connect the LVDT (57) to the actuator
piston rod.
49 Reinstall the scale (66) on the actuator and secure the scale indicator
on the clevis on the actuator piston rod. Adjust the position of the
scale to match the valve close position correctly.
50 Connect the hydraulic oil lines to the actuator.
51 Reconnect any I&C equipment disconnected prior to disassembly.
52 Remove the spring compression bolts (39).
53 Operate the MSV with hydraulic oil and ensure that the valve operates
smoothly.
54 Check and adjust the actuator close end over travel. The procedure
for measuring the close end over travel of the MSV servomotor is as
follows:
(i)
Ensure that the valve is fully closed and note the position of the
actuator piston rod on the scale (66).
(ii) Disconnect the actuator from the valve by removing the split pins,
washers and the linkage pin (53) at the operating lever (44).
Remove the linkage and disconnect the LVDT (57) from the
piston rod.
(iv) Record the difference in the readings in Steps (i) and (iii) between
the fully closed positions at the valve connected and
disconnected conditions as the closed end over travel.
MM-M05.02
Rev.001
Note
The actuator closed end over travel should be 6.1 mm.
55 Prior to return to service, the MSVs must undergo operational testing

for their control functions. During this process, the servo-system will
be adjusted, if necessary.

Mitsubishi
5-11
Chapter 5
64
1
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
57
62
64
58
34
66
5
63
12
61
27
26
20
13
14
36
56
15
10
22
28
59
16
24
25
65
17
Rev.001
23
2
STEAM CHEST
VALVE SEAT
MAIN VALVE
PILOT VALVE
PILOT VALVE NUT
SPRING SEAT
SHIM
SPRING
VALVE STEM
STRAINER
MAIN VALVE BUSHING
LOWER STEM BUSHING
UPPER STEM BUSHING
BONNET BUSHING
RETAINING BOLT
PLUG
PIN
LINER
SPRING GUIDE ROD
BONNET
STUD BOLT
SPHERICAL WASHER
NUT
EYEBOLT
GASKET
SPRING HOUSING
UPPER SPRING SEAT
LOWER SPRING SEAT
SPRING GUIDE
SPRING
STUD BOLT, NUT
LONG BOLT
STUD BOLT
SPHERICAL WASHER
NUT
CONNECTING ROD
PIN
BUSHING
SPLIT PIN
OPERATING LEVER
SPACER
NUT
LINKAGE PIN
BUSHING
LINKAGE PIN
DU BUSHING
LINKAGE PIN
DU BUSHING
LINKAGE PIN
STAY LINK
LIMIT SWITCH
LIMIT SWITCH LINK
LVDT
LVDT LINKAGE
GUIDE PLATE
SUPPORT
ACTUATOR
PIN
SUPPORT FASTENERS
JACK BOLT
SCALE
DU BUSHING
MM-M05.02
1
MPTD-3-0980
FIGURE 5-1

Mitsubishi
EXPLODED VIEW OF MAIN STOP VALVE
5-12
Chapter 5
PIN
LINER
STEP 1: REMOVE THE PIN

PLUG
SPRING GUIDE ROD

BONNET BUSHING
VALVE STEM
UPPER STEM BUSHING

INTERMEDIATE STEM BUSHING
PIN
SPRING
MAIN VALVE BUSHING
STEP 2: INSERT A BAR INTO THE
STEM HOLE AND UNSCREW
THE SPRING GUIDE ROD
LOWER STEM BUSHING
SHIM
BAR
PILOT VALVE NUT
MM-M05.02
Rev.001
MAIN VALVE
PILOT VALVE
SPRING SEAT
MPTD-4-0981
FIGURE 5-2
REMOVAL PROCEDURE FOR SPRING GUIDE ROD

Mitsubishi
5-13
Chapter 5
5.2
Disassembly and Reassembly of Governing Valve
CAUTION
a)
Preparation
If disassembly of a turbine GV becomes necessary, all associated
equipment shall be mechanically and electrically isolated and an
authorized clearance and work permit shall be in place prior to the
commencement of work. The following points are also to be considered
when preparing for disassembly and reassembly.


equipment.
Prepare the necessary maintenance floor around the GVs.

When using a crane, chain block etc, the center of gravity of the item
being lifted should be considered and the lift should be well balanced
and level.
b)
Disassembly
damage.
MM-M05.02
Rev.001
Tag all components for identification purposes and, if necessary bag or

wrap to prevent miscellaneous losses and ensure adequate protection.


Mitsubishi
5-14
Chapter 5
CAUTION
When separating joints and flanges use jacking bolts and wooden
mallets. Never apply force with hammers, chisels or screwdrivers.
All data is to be recorded during disassembly. During disassembly, make
reassembly.
1
Before disassembly, the as found close end over travel of the

hydraulic cylinder should be measured and recorded. The procedure
is as follows:
(i)
actuator piston rod indicated by the indicator on the scale (67)
secured to the actuator (57).
(ii) Disconnect the actuator (57) from the valve by removing the split
pins, washers and the linkage pin (54) at the actuator link (45).
Remove the linkage pin and disconnect the LVDT (65) from the
piston rod.
MM-M05.02
Rev.001
(iv) The amount of actuator piston rod movement beyond the valve
closed position is the closed end over travel.
2
Disconnect and tag all I&C equipment in the vicinity of the GV and the
GV actuator subject to maintenance.
covers or plugs.
Remove cladding and lagging as necessary to expose the main

flange and leak-off (flange) connections.
Detach the HP and LP leak-off connections (13 and 14).
Loosen and remove the actuator mounting bolts from the actuator
support (58). Remove the actuator (57) and transport it to the
lay-down area.
Remove the securing fasteners and remove the limit switch link (55),
the limit switch (56) and the limit switch support bracket.
Remove the split pins, washers and linkage pin (52) and separate the
actuator link (45) from the operating lever (41).
Install and tighten the spring compression bolts (34) to release the
spring compression from the connecting rod (22).

Mitsubishi
5-15
Chapter 5
10 Provide supports to the operating lever and the stay link (44). Remove
the split pins and the linkage pin (48) and disconnect the operating
lever and the stay link. Remove the DU bushing (49) from the stay link
if necessary.
11 Remove the split pins, washers and linkage pin (46) and then remove
the stay link (44) from the lug secured to the spring housing (23).
Remove the DU bushing (47) if necessary.
12 Rig and support the operating lever (41) for removal. Remove the split
pins and washers from the linkage pin (50) and disconnect the
operating lever and the knuckle (40). Lift and remove the operating
lever to the lay-down area. Remove the bushing (59) from the knuckle
if necessary.
13 Tap and remove the lock pin (62) which secures the knuckle (40) to
the connecting rod (22). Unscrew and remove the knuckle from the
connecting rod.
14 Loosen and remove the nuts and spring washers from the stud bolts
(37) at the upper spring seat (31). Slowly loosen the long bolts (35)
until the spring tension is completely released. Remove the long bolts
after the spring tension is completely released.
Do not loosen the long bolts from the spring housing until the stud
nuts are removed. Remove the long bolts only after releasing
complete tension from the springs. Spring pressure could force
the cover off and injure personnel in the vicinity of the work.
15 Rig and remove the upper spring seat (31), the compression springs
(33) and the lower spring seat (32) from the spring housing (23) using
the overhead crane. Transport the removed components to the
lay-down area. Remove the set screws (64) and then the oiless
bushing (63) from the upper spring seat if required.
16 Remove the spherical washers (29) and liner (28) from inside the
spring housing.
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17 Release and remove the nuts (25) which secure the spring housing to
the valve bonnet (8). Remove the spherical washers (26) from the
stud bolts (24).
18 Rig and remove the spring housing using the crane and transport it to
the lay-down area.
19 Remove the securing bolts (30) and then remove the bushing (27)
from the spring housing if required.
20 Cut and remove the lock wire (19) which secures the coupling (17) to
the special nut (16).

Mitsubishi
5-16
Chapter 5
21 Unscrew and remove the set screws (18) which lock the coupling with
the special nut.
22 Support the connecting rod (22) from the crane and unscrew the
coupling from the special nut. After the coupling is fully loosened, lift
and remove the connecting rod and the coupling together and
transport them to the lay-down area. Remove and secure the locating
pins (21) for use during reassembly.
23 Install bolt heaters into the stud bolts (9) and cap nuts (10).
Bolt heaters are electrical devices capable of causing

personnel injury or death if improperly used.
24 Heat and stretch the stud bolts (9) in accordance with the instructions
in Appendix F. Release and remove the cap nuts (10) from the stud
bolts and then remove the spherical washers (11).
25 Using the three jack bolts provided separate the joint between the
bonnet (8) and the steam chest (1) and lift the bonnet by about 5 mm.
26 Rig the bonnet (8) for removal and using the crane carefully take up
the slack in the rigging. It is important that the bonnet and valve
internals are removed with an accurate vertical lift and that there is no
significant side force due to uneven rigging.
27 Carefully take up the slack in the rigging and ensure that the bonnet is
evenly supported.
28 Remove the bonnet and valve internals from the steam chest as a
single assembly and transport it to the lay-down area. Remove and
discard the spiral wound gasket (60) from the steam chest.
CAUTION
Uneven removal of the bonnet can cause damage to the
bonnet bushings. If necessary, adjust rigging to ensure that
the bushings are not damaged during removal of the bonnet.
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29 Install a temporary cover over the opening to prevent foreign

30 Install the bonnet assembly vertically on temporary supports. Tap and
remove the lock pin (20) which secures the special nut (16) to the
valve stem (2).

Mitsubishi
5-17
Chapter 5
Note
Provide support to the valve stem assembly at the bottom while
removing the special nut to avoid falling.
31 Hold the stem suitably with a spanner at the flat surface provided just
below the special nut. Unscrew and remove the special nut from the
valve stem and withdraw the stem assembly from the bonnet at the
bottom.
32 Remove the lock pins (5) and then unscrew the main valve (3) from
the valve nut (4).
33 Remove the flow guide pins (61) and then remove the flow guide (12)
from the bonnet.
34 Unscrew and remove the lower stem bushing (6) from the bonnet if
inspection and/or replacement are necessary.
35 Remove the securing bolts (15) and remove the upper stem bushing
(7) from the bonnet if inspection and/or replacement are necessary.
c)
Reassembly
gaskets are to be replaced.
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1
Insert the valve nut (4) onto the valve stem (2) at the top end of the
stem and screw the valve (3) onto the valve nut at the bottom end.
After full tightness install the lock pins (5) to lock the main valve (3)
with the valve nut (4). Peen the lock pins to prevent them from
loosening.
Install the flow guide (12) into the bonnet (8) and secure it to the
bonnet using the flow guide pins (61). Peen the flow guide pins after
final installation to retain in position.
Replace the lower stem bushing (6) at the bottom end of the bonnet
and lock it by peening.
Carefully insert the valve stem assembly through the lower stem
bushing (6) at the bottom end of the bonnet. Take care to ensure that
the valve nut and the main valve slide smoothly through the lip at the
bottom end of the flow guide.

Mitsubishi
5-18
Chapter 5
Note
No binding or rubbing should occur as the stem assembly
passes through the bonnet. Any restriction for smooth entry
should be investigated and rectified.
7
Provide support to the stem assembly after it is fully inserted into the
bonnet. Replace the upper stem bushing (7) at the top end of the
bonnet and secure it with the retaining bolts (15).
Screw the special nut (16) at the top end of the valve stem (2). Align
the holes in the special nut and the valve stem and insert the lock pin
(20) through the aligned holes.
Remove the temporary cover, perform a final inspection of the steam

chest and remove any foreign material or debris that may have
entered.
10 Rig the bonnet (8) and transfer it to the work area in preparation for
replacement.
11 A seat contact check must be performed between the valve seat and
the main valve before final reassembly. To do this, the bonnet and
stem assembly must be inserted without a gasket into the steam
chest so that the flange faces contact fully without the bonnet stud
nuts being tightened.
Note
It will be necessary to use a suitable marker on either the valve
or the seat to indicate the contact area.
12 After ensuring seat contact, align the valve bonnet with the steam
chest and verify that the horizontal joint faces are parallel to within
0.8 mm.
CAUTION
Improper alignment of the bonnet and valve internals can cause
damage to the valve stem and the valve (plug). If necessary,
adjust rigging to ensure that the valve is not damaged during
replacement of the bonnet and valve internals.
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13 Lift the bonnet assembly and check that there is a continuous (100%)
contact band between the seating surfaces.
14 Place a new gasket (60) into the recess in the steam chest.
15 Repeat Step 12 noting the Caution. An even gap of about 1 mm
should be measured between the bottom surface of the bonnet and
the top surface of the steam chest when the bonnet is fully lowered
into position.

Mitsubishi
5-19
Chapter 5
16 Traverse the valve stem and ensure that the stem moves freely
without any binding before tightening the bonnet. Any restriction for
smooth movement should be investigated and rectified.
17 Install the spherical washers (11) and the nuts (10) onto the bonnet
stud bolts (9).
18 To close the joint, tighten the nuts in an alternating (side to side)
pattern to compress the gasket. Ensure that the bonnet and steam
chest faces are parallel to within 0.5 mm as the joint is tightened.

19 Heat the stud bolts (9) using bolt heaters in accordance with the
instructions provided in Appendix F. Perform the final tightening of the
nuts to the torque/bolt-stretch values specified in Appendix A.
20 Replace the starting bolts in their original positions. Do not tighten the
starting bolts.
21 Install the locating pins (21) on the special nut (16) and locate the
connecting rod (22) on the special nut. Hold the connecting rod
suitably to prevent falling.
22 Insert the coupling (17) at the top end of the connecting rod and screw
it onto the special nut. Do not tighten the coupling at this stage.
23 Replace the bushing (27) in its original location in the spring housing
(23) and secure it using the retaining bolts (30).
24 Rig the spring housing (23) and align it above the bonnet. Lower the
spring housing slowly and carefully such that the connecting rod (22)
slides smoothly into the bushing (27).
25 After ensuring that that the spring housing is properly seated install
the spherical washers (26) and nuts (25) onto the studs (24). Tighten
the nuts in sequence to ensure proper seating.
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26 Replace the liner (28), spherical washers (29), lower spring seat (32),
springs (33) and upper spring seat (31) into the spring housing in the
order mentioned.
27 Install the spherical washers (36) and the long bolts (35) onto the
upper spring seat and tighten the bolts uniformly. Ensure that the
upper spring seat is correctly seated.
28 Replace the spring washers (38) and nuts (39) onto the stud bolts
(37) and tighten them in sequence.

Mitsubishi
5-20
Chapter 5
29 Install the bushing (63) into the slot in the upper spring seat and
secure it with the set screws (64).
30 Install and tighten the spring compression bolts (34) and set the valve
stem free from the spring closing force.
31 Manually operate the connecting rod (22) and ensure that the valve
stem moves smoothly. Any problem for free movement should be
investigated and rectified.
32 Fully tighten the coupling (17) onto the special nut (16) at this stage.
Install and tighten the set screws (18) to secure the coupling to the
connecting rod.
33 Install the lock wire (19) into the holes provided in both the coupling
and the special nut to prevent the coupling from loosening.
34 Install the knuckle (40) onto the connecting rod (22). Align the holes in
the knuckle and the connecting rod and insert the lock pin (62) into
the aligned holes. Retain the lock pin (62) from loosening by peening.
35 Rig the actuator assembly (57) and lift it into the position from where it
was removed. Secure the actuator to the actuator support (58) using
the fasteners.
36 Install the bushing (59) and align the operating lever (41) with the
knuckle (40). Insert the linkage pin (50) and secure it with washers
and split pins.
37 Connect the stay link (44) to the spring housing by installing the
linkage pin (46) and DU bushing (47). Secure the linkage pin with
washers and split pins. Connect the stay link with the operating lever
using the linkage pin (48), DU bushing (49), washers and split pins.
38 Connect the actuator link (45) to the operating lever using the linkage
pin (52), DU bushing (53), washers and split pins.
39 Set the actuator piston rod to the position noted during disassembly
and then connect the actuator link to the actuator piston rod using the
linkage pin (54), washers and split pins.
40 Reconnect the HP and LP leak-off pipe work (13 and 14).
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43 Reconnect the I & C equipment removed prior to disassembly except
the linkage for the limit switch (56).
44 Install the scale (67) on the actuator and set the indicator to show the
closed position of the valve (zero position on the scale).

Mitsubishi
5-21
Chapter 5
45 Operate the valve with the actuator and ensure that it moves
smoothly.
46 The closed end over travel should be measured and adjusted at this
stage. The procedure for measuring the as built closed end over
travel of the actuator is same as follows:
i)
actuator piston rod indicated by the indicator on the scale (67).
ii)
Remove the pin (54) and disconnect the actuator link (45) from
piston rod and move the hydraulic cylinder to the closed position.
iii) Measure and record the difference between the closed positions
of the hydraulic cylinder piston rod at the valve connected and
disconnected positions.
iv) The amount of actuator piston rod movement beyond the valve
closed position is the closed end over travel.
Note
There should be 6+2/-0 mm of closed end over travel. If
necessary, make necessary adjustments by adjusting the
position of the clevis on the actuator piston rod.
47 Reconnect the linkage (55) from the operating lever to the limit switch
assembly (56) and the LVDT ink (66) to the LVDT (65) and then
release the valve for service.
48 Release and remove the spring compression bolts (34) and store
them safely for future use.
49 Ensure that the valve is closed and measure the spring height in the
spring housing.
Note
The spring height should be 4802 mm. If necessary, make
necessary adjustments by machining the liner (28) below the
lower spring seat.
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50 Prior to return to service, the GVs must undergo operation testing for
their control functions. During this process the actuator will be
adjusted, if necessary.

Mitsubishi
5-22
Chapter 5
48
51
50
59
17
41
42
62
19
40
18
22
12
64
63
21
35
4
16
36
39
15
38
20
7
31
2
33
29
32
3
28
49
10
47
46
44
53
30
11
54
27
68
14
45
37
13
24
23
67
25
8
58
66
65
26
61
57
60
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34
M P T D -3 -0 9 8 2
FIGURE 5-3

Mitsubishi
EXPLODED VIEW OF GOVERNING VALVE
5-23
Chapter 5
5.3
Disassembly and Reassembly of Reheat Stop Valve
CAUTION
a)
Preparation
If disassembly of a RSV becomes necessary, all associated equipment
Have all necessary assembly drawings and documents (log sheets,

field record book, etc.) ready prior to start of work.

temporary supports, etc.) to remove and store the various parts of the
equipment.

b)
Disassembly
damage.
CAUTION
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reassembly.

Mitsubishi
5-24
Chapter 5
The RSV can be disassembled while the actuator is still mounted on the
actuator support. Accordingly, Steps 3 and 4 from the following procedure
will not be necessary if the actuator and its support do not require removal.
Also, due to the location of the leak-off connection on the RSV, Steps 5
and 6 will not be necessary unless the actuator support is to be removed.
1
Before disassembly, the as found closed end over travel of the

actuator should be measured and recorded. The procedure is as
follows:
(i)
Ensure that the RSV is fully closed. Note the position of the
actuator piston rod as indicated by the indicator on the scale (72)
secured to the actuator (45). Refer to View C in Figure 2-14 for
details.
(ii) The spring housing (34) is provided with two spring compression
bolts (44) at the flange (46). Tighten these spring compression
bolts the minimum amount necessary to remove the closing force
from the springs (37).
(iii) Disconnect the actuator from the valve by removing the link pin
(32) from the joint between the connecting rod (35) and the link
(29).
(iv) Fully close the actuator at the valve disconnected position. Note
the position actuator piston rod on the scale (72) at this new
position.
Disconnect and tag all I&C equipment in the vicinity of the RSV and/or
the actuator subject to maintenance.
covers or plugs.
Rig the actuator (45) and remove the actuator mounting fasteners.
Remove the actuator and transport it to the lay-down area.
Remove cladding and lagging as necessary to expose the main

flange and leak-off (flange) connections.
Unbolt and detach the stem leak-off connection (68) from the actuator
end of the valve.
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(v) The difference between the two readings at the actuator fully
closed and the valve fully closed positions is the as found
actuator closed end over travel.

Mitsubishi
5-25
Chapter 5
Remove the split pins, washers and linkage pin (30) connecting the
link (29) and the lever (27) and then remove the link (29). Remove the
bushings (31) from the link if replacement is necessary.
Remove the nuts (7) and the spherical washers which secure the
valve cover (5) to the body (1).
Rig and remove the valve cover and transport it to the lay-down area.
Remove and discard the spiral wound gasket (61).
10 Install eyebolts in the two M24 eyebolt holes on the valve arm (3) and
one M12 eyebolt hole on the shaft of valve disc (4). Attach slings to
the eyebolts and support the valve disc and arm assembly in the
horizontal position using the crane. In addition, arrange wood blocks
or similar packing material such that it will be secure when
disassembled from the stem (2).
11 Remove the hydraulic oil supply and drain connections on the trip pilot
valve (20) and cap all connection points to reduce the possibility of
contamination.
12 Unbolt and detach the stem leak-off connection flange at the trip pilot
valve end. Remove the trip pilot valve (20) and transport it to the
lay-down area.
13 Remove the nuts (9) and spherical washers (57) which secure the
bearing cover (8) to the valve body (1). Remove and discard the spiral
wound gasket (59).
14 Using the starting bolts (10), free the bearing cover (8) together with
the detached stem leak-off line from the trip pilot valve. Support the
bearing cover assembly suitably and draw it completely out of the
valve body.
15 Working at the opposite end of the valve, loosen the nuts (26) and
release the spring compression from the spring (24).
16 Remove the outer spring seat (23), spring (24), thrust bearing (22)
and inner spring seat (21). Unscrew and remove the spring bolt (25)
secured to the valve stem (2).
Alternatively the stem can be pushed out by using a jack-bolt or a

hammer at the actuator end. It will be necessary to use a brass or
copper section between the hammer and the stem to prevent damage
to the stem.
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17 Using an eyebolt or a draw-bolt secured to the stem at the trip pilot

valve end, withdraw the stem (2) out of the arm (3) and body (1).

Mitsubishi
5-26
Chapter 5
Note
The valve stem must be withdrawn only at the trip pilot valve
end of the RSV.
Note
It will be necessary to provide a support to the shoulder ring
(18) and the lever (27) so that they are secured when the stem is
released. Finally the stem will also need support as it exits the
valve body.
18 Transport the lever (27) to the lay-down area after the stem is moved
out of the lever.
19 Remove the key fixing bolts and then remove the arm keys (6) and
the lever keys (28) from valve stem.
20 Remove the shoulder ring (18) and the stopper ring (19) and store
them in the lay-down area.
21 If it is necessary to remove the disc (4) from the valve arm (3), rig and
remove the arm and disc assembly through the open top of the valve
body.
22 Remove the lock pins (56), loosen the nut (55) and separate the valve
disc from the valve arm.
23 Remove the bushings (14, 15, 16 and 17) from their locations and
transport them to the lay-down area for necessary inspection.
24 Install temporary covers over all openings to prevent foreign materials
or debris from entering the valve body.
25 If there is a requirement to dismantle the stopper assembly for the
lever (27), proceed as follows (refer to Detail D in Figure 2-14):
(i)
Remove the split pin and loosen the nut (49) to release the
compression force from the Belleville washers (50).
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(ii) After completely releasing the Belleville washers, remove the nut
(49) and withdraw the stopper rod (48) from inside the actuator
support (11).
(iii) Remove the set screw (53), unscrew and remove the outer spring
seat (51), Belleville washers (50) and inner spring seat (52) from
the stopper guide (47).
(iv) Unscrew and remove the guide (47) and then the spacer (54) if
required.

Mitsubishi
5-27
Chapter 5
26 If there is no requirement to separate the spring assembly from the

actuator support (11), proceed as follows:
(i)
Rig the actuator support (11) with the spring assembly. Carefully
take up the slack in the rigging in preparation for removal of the
mounting fasteners.
(ii) Working in an alternating side to side pattern, remove the nuts

(13) and spherical washers which secure the actuator support to
the valve body.
(iii) Draw the actuator support (11)/bearing support (12) assembly
with the spring housing assembly (34) off the stud bolts (12) and
(iv) Remove and discard the spiral wound gasket (58).
27 If it is required to disassemble the spring assembly, ignore Step 26
and proceed as follows:
(i)
Unscrew the spring compression bolts (44) fully.
(ii) Unscrew and remove the bolts (43) which secure the actuator
mounting flange (46) to the spring housing (34).
(iii) Slowly loosen the three long bolts (43a) until the spring
compression is fully released.
(iv) Rig or support the spring housing suitably and loosen the spring
housing flange fasteners (42). Remove the spring housing as an
assembly and transport it to the lay-down area.
Do not loosen the spring housing bolts until complete tension is

released from the spring.
(v) Support the spring housing assembly in a horizontal position,
remove the long bolts (43a) and then remove the flange (46).
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(vi) Unscrew and remove the retainer ring (41) from the connecting
rod (35) and then remove the spherical washers (40), spring seat
(38), springs (37) and stopper (39) from the spring housing.
(vii) Withdraw the connecting rod from the spring housing. Tap and
remove the lock pin (62) and then unscrew the connecting rod
end (36) from the connecting rod, if required.
(viii) Remove the bushing (63) from the spring housing if inspection or
replacement is required.

Mitsubishi
5-28
Chapter 5
c)
Reassembly
1
If dismantled during disassembly, reassemble the stopper assembly

as follows:
(i)
Replace the spacer (54) and the guide (47) into the support (11).
(ii) Insert the stopper rod (48) into the guide (47) from inside the
support (11).
(iii) Insert the inner spring seat (52) and the Belleville washers (50)
onto the stopper rod.
(iv) Screw the outer spring seat (51) into the guide and lock it with the
set screw (53).
If the spring assembly was dismantled during disassembly, install the
bushing (63) and insert the connecting rod (35) into the spring
housing (34) from the actuator end.
When the connecting rod protrudes the bushing (63), replace the liner
(64) and screw the connecting rod end (36) into the connecting rod.
Install the springs (37), stopper (39), spring seat (38) and spherical
washers (40) into the spring housing at the actuator end. Secure
these components to the connecting rod using the retainer ring (41).
Replace the flange (46) and tighten it using the three long bolts (43a)
until the spring is compressed and the flange joint is closed. Install the
short bolts (43) and tighten the flange (46) fully.
If removed during disassembly, secure the bearing support (12) to the

support (11) using the cap screws (69). Replace a new gasket (58) on
the valve body and position the assembled actuator support (11) (with
the bearing support). Replace the spherical washers and the nuts (13)
and tighten the nuts sufficient to hold the support rigidly.
Lift the spring assembly (assembled in Steps 3~5) and secure it to the
support (11) using the fasteners (42).
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Mitsubishi
5-29
Chapter 5
Check surface contact between the mating surfaces of the bushing

(15) and the shoulder ring (18) and ensure uniform contact all around.
Lap the surfaces if required.
10 Install and secure the bushings (15 and 16) in their original locations
in the bearing support (12) and the bushing (17) in the actuator
support (11), if removed during disassembly.
11 Reassemble the disc (4) and the arm (3), if dismantled during
disassembly, as follows:
(i)
Using Engineers blue, check the surface contact between the

back-seat surfaces on the arm (3) and the disc (4). Check for
100% contact and lap the surfaces if necessary.
(ii) After obtaining a satisfactory surface contact between the

back-seat surfaces, insert the disc into the arm.
(iii) Install the special nut (55) and tighten it until a gap of 0.33~0.38
mm is obtained between the valve arm and the special nut. Refer
to Figure 4-8 for clearance detail.
(iv) Install the two lock pins (56) in the joint between the disc and the
special nut.
Note
If the original holes in the nut and the valve arm do not match,
drill and ream new holes and then install the pins.
12 Remove the temporary covers from the valve and replace the disc
and arm assembly (assembled in Step 11 above) into the valve body.
13 Replace the arm keys (6) into the key slots and secure them to the
stem using the key fixing bolts.
14 Replace the stopper ring (19) in its original location on the stem, if
removed during disassembly.
15 Support the disc and the arm assembly using eyebolts and wood
packing in the same manner as disassembly. Insert the stem (2) into
the arm (3) from the trip pilot valve end. Take care to align the keys
(6) with the key slots while inserting the stem.
Note
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It will be necessary to use soft hammer and/or with soft packing

to tap the stem into the arm during insertion.
16 When the stem protrudes from the other side of the arm, install the
shoulder ring (18) onto the protruding stem.

Mitsubishi
5-30
Chapter 5
17 Continue to insert the stem through the bearing support (12) and the
support (11) secured to the actuator end of the valve body.
Note
Take care not to damage the bushings (15 and 16) during this
operation and ensure that the arm, shoulder ring and the
stopper ring are correctly located.
18 When the stem protrudes through the bushing (16), install the lever
(27) between the bushings (16 and 17) taking care to align the key
slots on the valve stem and the lever. Simultaneously install the keys
(28) between the stem and the lever and secure them with the
key-fixing screws. Continue the stem insertion until the stem is
located correctly in the bushing (17).
19 Insert the bushing (14) onto the valve stem in its original location at
the stem removal end. Install a new spiral wound gasket (59) and
then insert the bearing cover (8) into the valve body. Ensure that the
bearing cover engages the bushing (14) smoothly during insertion.
20 Install the spherical washers (57) and the nuts (9) after the bearing
cover is fully inserted and tighten the nuts in accordance with
Appendix F to the torque value specified in Appendix A.
21 Tighten the nuts (13) holding the support (11) in accordance with
Appendix F to the torque value specified in Appendix A.
22 Screw the spring bolt (25) into the stem and secure it with the lock nut
(60). Install the inner spring seat (21), thrust bearing (22), spring (24)
and outer spring seat (23) and tighten them with the nut (26) to the
position marked during disassembly. Replace the lock nut to secure
the assembly.
23 Replace a new spiral wound gasket (61) and then replace the main
cover (5) onto the valve body. Replace the spherical washers and
nuts and tighten the studs (7) in accordance with Appendix F to the
torque value specified in Appendix A.
24 Replace the RSV actuator assembly (45) and secure it to the actuator
flange (46).
26 Install the spring compression bolts (44) and tighten them uniformly to
compress the springs (37) and to release the spring force on the
connecting rod (35).
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25 Replace the bushings (31) and connect the link (29) to the lever (27)
using the linkage pin (30), washers and split pins.

Mitsubishi
5-31
Chapter 5
27 Replace the bushings (33), align the holes between the connecting
rod end (36) and the link (29) and then install the linkage pin (32),
washers and split pins to complete the linkage between the link and
the connecting rod.
28 Replace the trip pilot valve (20) and reconnect the stem leak-off
connection to the trip pilot valve.
29 Reconnect the stem leak-off connection (68) on the bearing support
(12) at the actuator end.
31 Connect the hydraulic oil lines to the actuator and the trip pilot valve.
32 Secure the limit switch linkage rod (70) to the connecting rod end (36)
and then install the linkage (71) between the linkage rod (70) and the
limit switch (67).
34 Replace the scale (72) on the actuator and adjust it to match the close
position of the valve.
35 Release the spring compression bolts (44), operate the RSV by the
actuator and ensure smooth valve operation.
36 The as found closed end over travel of the actuator should be
measured and recorded at this stage. The procedure is as follows:
(i)
Operate the RSV by the actuator and close the valve fully.
Ensure that the indicator on the actuator position end reads zero
on the scale (72).
(ii) Ensure that the spring compression bolts (44) are tightened to
remove the closing force from the springs (37). Disconnect the
actuator from the valve by removing the link pin (32)).
(iii) Fully close the actuator at this valve disconnected position. Note
the reading of the actuator piston rod at this new position.
(iv) The difference between the two measurements at the actuator
fully closed and the valve fully closed positions is the actuator
closed end over travel.
The closed end over travel should be 61 mm. Any deviation

should be adjusted by altering the thickness of the liner (64)
provided below the connecting rod end (36).
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Note

Mitsubishi
5-32
Chapter 5
37 If the stopper assembly was dismantled during disassembly, set the

stopper assembly as follows:
(i)
Set the stopper (48) and nut (49) such that there is no axial
clearance and then lock the nut and the stopper with the split pin
(73).
(ii) Open the valve fully using the actuator and then screw-in the
outer spring seat (51) until the Belleville washers (50) are just
compressed.
(iii) Close the valve fully, mount a dial gauge on the guide (47) or the
support (11) and set the stem of the dial gauge onto the end of
the stopper.
(iv) Loosen the set screw (53) and tighten the outer spring seat (51)
to set a gap of 2.8+0/-0.3 mm between the outer spring seat (51)
and the nut (49).
(v) Open the valve and ensure that the stopper movement is
2.8+0/-0.3 mm in the valve full open position. Tighten the set screw
(53) and peen it to lock.
(vi) Confirm that the lever touches the bottom end of the stopper in
the valve full open position.
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38 Prior to return to service, the RSVs must undergo operational testing

of the control functions.

Mitsubishi
5-33
Chapter 5
49
50
73
51
52
55
7
47
53
48
54
12
11 70
71
15
67
16
31
42
39
60
25
40
29
41
13
21
64
36
35
43a
43
66
69
27
38
46
72
63
62
42
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45
34
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FIGURE 5-4

Mitsubishi
EXPLODED VIEW OF REHEAT STOP VALVE
5-34
Chapter 5
5.4
Disassembly and Reassembly of Interceptor Valve
CAUTION
a)
Preparation
If disassembly of an ICV becomes necessary, all associated equipment


equipment.

b)
Disassembly
damage.
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Mitsubishi
5-35
Chapter 5
CAUTION
reassembly.
1
Disconnect and tag all I&C equipment in the vicinity of the ICV and the
ICV actuator subject to maintenance.
covers or plugs.
Before proceeding with further disassembly, the as found closed end

over travel of the actuator should be measured and recorded. The
procedure is as follows:
(i)
Disconnect the linkages for the limit switch (42) and the LVDT
(43) from the cross-head (21).
(ii) Install a dial indicator at the top surface of the actuator base to
indicate vertical movement of the actuator base.
(iii) Install a second dial indicator to monitor vertical movement of the
cross-head (21).
(iv) Install the support plates (29) and secure them to the spring seat
(28) using the bolts (30).
(v) Install the three spring compression bolts (special bolts) (32) and
the spring compression nuts (33) as indicated in Figure 2-17.
(vi) Tighten the spring compression nuts (33) and compress the
springs (27) and set the valve stem (14) free from the spring
closing force.
(vii) Rig the actuator (34) to a hoist or crane hook and loosen the bolts
(37) which secure the actuator to the spring housing (17).
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(viii) Slowly raise the actuator in small increments until the second dial
indicator shows movement at the cross-head (21). This will
establish the point at which the valve stem starts to rise.
(ix) The reading on the first dial indicator corresponding to the start of
stem lift will indicate the actuator movement beyond the valve
closed position. This reading is the closed end over travel of the
actuator.

Mitsubishi
5-36
Chapter 5
Cut and remove the lock wire connecting the limit switch and the
LVDT linkage arm bolts (38 and 38a). Unscrew and remove the
linkage arm bolt (38) for the limit switch (42) and the linkage arm bolt
(38a) for the LVDT (43).
Remove cladding and lagging as necessary to expose the bonnet

flange and stem leak-off (flange) connections.
Unbolt and disconnect the stem leak-off connection (16).
Tighten the spring compression nuts (33) and raise the spring seat
(28) to create sufficient space for the removal of the cross-head (21).
This will also lift the upper spherical washer (23a) with the spring seat
and expose the lock pin (36) for removal.
Tap and remove the lock pin (36) which secures the actuator piston
rod (35) and the cross-head (21).
Ensure that the actuator (34) is in the lifted condition for measuring
closed end over travel in Step 1. Holding the piston rod at the flat
surface near the cross-head unscrew the cross-head (21) until the
piston rod (35) is freed from the cross-head.
Note
Ensure that the main valve (2) doesnt touch the seat while
turning the cross-head. If the main valve touches the seat, stop
rotation and lift the actuator further to create clearance between
the main valve and the seat.
10 Rig and remove the actuator (34) and transport it to the lay-down
area.
11 Rig the spring housing (17) for removal. Unscrew and remove the
screws (19) and spherical washers (20). Lift the spring assembly and
12
If further disassembly of the spring assembly is essential, proceed

as follows:
(i)
Invert and support the spring assembly such that the spring
housing cover (45) rests on the floor and the flanged end is up.
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(ii) Uniformly loosen the spring compression nuts (33) until complete
spring compression is released. Loosen the nuts further and
remove them from the spring compression bolts (32).
(iii) Unscrew the bolts (30) and remove the support plates (29) from
the spring seat (28).
(iv) Rig and remove the spring seat (28) and the springs (27) from
inside the spring housing (17).
(v) Unscrew the bolts (31) and remove the upper spherical washer
(23a) from the spring seat.

Mitsubishi
5-37
Chapter 5
13 Remove the lower spherical washer (23), DU thrust washer (25) and
spacer ring (22) from the cross-head.
Note
Before further disassembly of the ICV internal parts, it will be
necessary to measure the as found main valve travel.
14 The procedure for measuring the as found main valve travel is as

follows:
(i)
Ensure the ICV is fully closed and mark a reference point on the
valve stem (14) where it protrudes the stem bushing (15).
(ii) Place a bar through the cross-head (21) and lift the cross-head
together with valve stem (14). Lift the valve stem until the valve
stem (14) makes contact with the shoulder in the stem bushing
(15).
(iii) Mark a second reference point on the valve stem as marked for
the first reference point in Step (i).
(iv) Measure the distance between the two reference marks on the
valve stem. Record this value as the as found main valve travel.
15 Lower the valve stem until it rests on the seat. Tap and remove the
lock pin (26) which secures the cross-head (21) to the valve stem (14).
Unscrew and remove the cross-head from the valve stem.
16 Remove the liner (24) from the cross-head and store it safely for use
during reassembly.
17 Loosen and remove the nuts from the bonnet studs (11) in
accordance with the instructions in Appendix F and then remove
spherical washers (12).
18 Rig the valve bonnet (8) for removal and carefully take up the slack in
the rigging.
19 Using the jack bolts (13) separate the valve bonnet (8) from the valve
body (1) by about 5 mm. Lift the bonnet by the crane and transport it
to the lay-down area.
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CAUTION
Lack of preparation and care during the removal of the bonnet
can cause damage to the valve and/or bushing. If necessary,
adjust rigging to ensure a safe vertical lift.
20 Remove and discard the spiral wound gasket (44) between the
bonnet and the valve body.

Mitsubishi
5-38
Chapter 5
21 Remove the strainer (9) and the stem bushing (15) from the bonnet
(8) if inspection or replacement is necessary.
22 Remove the set pins (7) and then remove the valve bushing (6) from
the bonnet if inspection or replacement is necessary.
23 Install eyebolts into the two eyebolt holes provided in the top surface
of the main valve (2). Lift the valve internals as an assembly
containing the valve stem (20), main valve (2), retainer (3), etc.
24 Provide appropriate support to the main valve at the bottom. Using
the special tool (box spanner) identified in Appendix C, unscrew and
remove the retainer (3) from the main valve (2).
25 Remove the stem (14) and the retainer (3) from inside the main valve.
26 Remove the piston rings (4) and guides (5) from the main valve if
inspection or replacement is necessary.
27 Install a temporary cover over the valve opening to prevent foreign
c)
Reassembly
Position the main valve (2) in the vertical position and insert the stem
(14) into the main valve.
Slide the retainer (3) through the top end of the valve stem and screw
it to the main valve. Tighten the retainer to the main valve by
tightening it with the special tool provided. Peen the joint between the
retainer and the main valve to retain the retainer in position.
Replace new piston rings (4) and the guides (5) into the slots on the
main valve (2) if removed during disassembly.
Rev.001
Replace the main valve bushing (6) (if removed during disassembly)
and secure it to the bonnet using the set pins (7).
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Replace the strainer (9) (if removed during disassembly) and secure it
to the bonnet using the retaining pins (10).

Mitsubishi
5-39
Chapter 5
Replace the stem bushing (15) (if removed during disassembly) and
secure it to the bonnet by peening.
Remove the temporary cover and perform a final inspection of the

valve body. Remove any foreign materials or debris that may have
entered.
Rig the main valve/stem assembly (assembled in Steps 2~4) and

position it over the valve body (1). Slowly lower the main valve/stem
assembly into the valve body until the main valve is located correctly
on the seat.
10 Remove the slings and eyebolts from the main valve/stem assembly.
11 Replace a new spiral wound gasket (44) into the recess on the valve
body.
12 Rig the bonnet assembly (assembled in Steps 5~7) and transfer it to
the work area in preparation for replacement.
13 Align the bonnet assembly over the valve body. Slowly lower the
bonnet assembly carefully ensuring that the stem bushing (15)
engages the valve stem and the bonnet engages the studs (11)
correctly. Continue to lower the bonnet until it is located correctly on
the valve body.
Note
The bonnet should be replaced without any binding or rubbing or
the need to use force. Any problem should be investigated and
resolved before continuing.
14 Verify that the faces are parallel to within 0.03~0.23 mm while

inserting the bonnet into the valve body. Perform an initial pull down
with four nuts.
CAUTION
Improper alignment of the bonnet can cause damage to the valve
internals. If necessary, adjust rigging to ensure smooth vertical
movement.
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15 Install the spherical washers (12) and the nuts onto the stud bolts (11).
Tighten the nuts in accordance with the torque value specified in
Appendix A.
Note
While closing the joint, tighten nuts in an alternating (side to side)
pattern to compress the gasket. Ensure that the bonnet and valve
body faces are parallel to within 0.5 mm as the joint is tightened.

Mitsubishi
5-40
Chapter 5
16 Before proceeding with reassembly further, it will be necessary to

measure the travel for the main valve. Repeat the procedure given
Step 14 in the disassembly section.
The designed value for main valve travel is 173 4 mm. If the main
valve travel is outside these tolerances, the valve should be
disassembled to correct the travel. Adjust the main valve travel by
machining the shoulder in the stem bushing (15).
17 Replace the cross-head (21) onto the valve stem and tighten it.
18 Align the holes in the cross-head and the stem and then insert the
lock pin (26). Peen the lock pin to retain it in position.
19 Reassemble the spring assembly as follows:
(i)
Install the spring compression bolts (special bolts) (32) in the

spring housing (17) and position the spring housing such that the
flanged end faces upwards.
(ii) Secure the upper spherical washer (23a) to the spring seat (28)
using the bolts (31).
(iii) Secure the support plates (29) to the spring seat using the bolts
(30).
(iv) Replace the springs (27) and the spring seat into the spring
housing.
(v) Install the spring compression nuts (33) onto the spring
compression bolts. Progressively tighten the nuts to compress
the springs to the position in Step 3 (vi) in the disassembly
procedure.
20 Install the spacer ring (22), DU thrust washer (25), lower spherical
washer (23) and liner (24) into their locations on the cross-head.
21 Rig the spring housing assembly (assembled in Step 19) and replace
it onto the bonnet (8). Locate the spring housing on the bonnet using
the locating pins (18). Ensure that the recess on the bonnet correctly
engages spring housing base.
Rev.001
23 Rig the actuator assembly (34) and secure it to the spring housing
(17) using the mounting fasteners (37). Ensure that the piston rod (35)
is in the valve close position (piston rod extended position).
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22 Install the spherical washers (20), tighten the screws (19) to the
torque value specified in Appendix A and secure the spring housing to
the bonnet.
24 Align the holes in the piston rod and the cross-head and insert the
lock pin (36) through the aligned holes.

Mitsubishi
5-41
Chapter 5
25 Loosen the spring compression nuts (37) progressively to reduce the

compression to the normal close position value. Confirm that this
position matches with the mark noted prior to the disassembly.
Ensure that the upper spherical washer (23a) seats correctly on the
lower spherical washer (23).
26 Loosen and remove the spring compression nuts (33), spring
compression bolts (32) and support plates (29) from the spring
housing after final reassembly. Preserve these components for the
subsequent disassembly of the valve.
27 Screw the arm bolts with rollers (38 and 38a) onto the cross-head
(21).
28 Replace and secure the limit switch (42) onto the bracket on the
spring housing. Reconnect the linkage between the arm bolt (38) and
the limit switch.
29 Replace and secure the LVDT (43) onto the spring housing.
Reconnect the linkage between the arm bolt (38a) and the LVDT.
30 Secure the arm bolts (38 and 38a) by interlocking them with a lock
wire.
31 Replace and secure the indicator (40) onto the cross-head and adjust
the scale (41) to match the close position (zero) of the valve.
34 Reconnect the stem leak-off pipework (16).
36 Operate the valve with the actuator and ensure that it moves
smoothly.
37 Perform a close end over travel measurement as done during
disassembly.
Note
38 Prior to return to service, the ICVs must undergo operational testing

for the control functions. During this process, the servo-system will be
adjusted, if necessary.
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The close end over travel should be 6 1 mm. If

necessary, adjust the close end over travel by machining
the liner (24).

Mitsubishi
5-42
Chapter 5
34
13
15
37
35
11
32
14
3
45
12
27
2
17
41
40
38
5
8
4
39
43
18
19
20
42
16
31
10
38a
28
29
44
30
33
23
23a
25
11
22
21
6
36
26
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24
FIGURE 5-5

Mitsubishi
EXPLODED VIEW OF INTERCEPTOR VALVE
5-43
Chapter 5
5.5
Disassembly and Reassembly of Steam Admission Valve

Actuators
CAUTION
a)
Preparation
If the actuator of a turbine steam admission valve disassembly becomes
necessary, all associated equipment shall be mechanically and electrically
isolated and an authorized clearance and work permit shall be in place
prior to the commencement of work. The following points are also to be
considered when preparing for disassembly and reassembly.
b)
Have all necessary assembly drawings and documents (log sheets,

field record book, etc.) ready prior to start of work.

temporary supports, etc.) to remove and store the various parts of the
equipment.
Disassembly
It is essential that a clean area (preferably a dedicated clean room) is
established for disassembly and reassembly of the actuator as a minimum
requirement. Any particulate contamination will compromise the
performance and reliability of the equipment.
The individual control components such as the servo valve need special
care due to special overhaul and inspection techniques and small
clearances. Site disassembly is not recommended.
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The operating authority may wish to consider developing an overall policy

for the maintenance of this equipment, in consultation with the
manufacturer. This could include, for example, in service maintenance of
the accumulators where the consequences of poor performance have
significant implications but cannot be easily predicted. This is a
specialized area of maintenance where reference to the manufacturer will
probably be necessary.
The MSV, GV, RSV and ICV actuators and peripheral equipment are
similar. Apparent variations are largely but not exclusively due to
differences in configuration. These variations arise because of the
differences in the physical layout and service duties of the operated valves.
The procedures in this section are generic procedures applicable to all
actuators.

Mitsubishi
5-44
Chapter 5
CAUTION
When separating joints and flanges use jacking bolts and
wooden mallets. Never apply force with hammers, chisels or
screwdrivers.
reassembly.
For disassembly/reassembly, refer to the following drawings, as
necessary.
Figure 2-8 shows a MSV actuator assembly. Refer to Figure 2-6 for an
illustration of the orientation relative to the valve.
Figure 2-11 shows a GV actuator assembly. Refer to Figure 2-9 for an
Figure 2-16 shows a RSV actuator assembly. Refer to Figure 2-14 for an
Figure 2-19 shows an ICV actuator assembly. Refer to Figure 2-17 for an
Figure 5-6 shows the general sequence for disassembly of an actuator
into the main component parts. In combination with the appropriate
specific drawings referenced above, it can be used for any of the four
applications.
Figure 5-7 shows the disassembly sequence for the hydraulic cylinder
assembly.
Note
The disassembly and reassembly procedures in this section are
relative to the MSV actuator but they are also applicable to the GV,
RSV and ICV actuators.
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1
Remove the cover for the cover assembly (8) which is mounted on the
hydraulic valve block assembly (3).
The dump valve (6) and the servo valve (7) can now be disconnected
and removed from their locations in the cover assembly (8).
Remove the cover assembly (8) from the valve block assembly (3).
The filter (5) and the solenoid valve (16) (if fitted) can now be
removed from the valve block assembly (3).

Mitsubishi
5-45
Chapter 5
Remove the manifold (9) from the valve block assembly (3).
Remove the accumulator (4) from the pipe block (2), if fitted.
Remove the pipe block (2) from the valve block assembly (3).
Separate and remove the valve block (3) and the pipe block (2) from
the hydraulic cylinder assembly (1).
The individual hydraulic components of the actuator have now been

disassembled.
10 Remove the linkage connection from the hydraulic cylinder assembly.

11 Remove the hydraulic cylinder from its support.
12 The procedure for disassembly of the hydraulic cylinder assembly is
as follows:
(i)
Working at the piston rod end, remove the screws (5), seal cover
(6), seal casing (7) and bushing (8).
(ii) Remove the oil seals (9), dust seal (10) and O-ring (11) from the
components removed in Step (i).
(iii) Working at the head end of the cylinder, remove the lock wire
(12) and then the nuts (13) and washers (14) from the tie rods
(15).
(iv) Remove the head end cover (3) and withdraw the piston rod
assembly (16 ~ 21) from the cylinder tube (2).
(v) Remove the lock nut (18), lock washer (17), piston nut (19) and
then remove the piston (20) from the piston rod (16).
(vi) Remove the O-ring (11) and the piston seal rings (21) from the
piston if replacement is necessary.
(vii) Remove the O-ring (11) from the head end cover.
(viii) Remove the rod end cover (4) from the cylinder.
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c)
Reassembly
maintained as specified.
Discard all O-rings, dust seal and oil seals and replace them with new
ones during reassembly.

Mitsubishi
5-46
Chapter 5
All contact surfaces are to be cleaned before starting reassembly and new
gaskets are to be used.
1
Reassemble the hydraulic cylinder assembly as follows:

(i)
Replace the piston seal rings (21) and the O-ring (11) in the
piston (20) if removed during disassembly.
(ii) Insert the piston (20) onto the piston rod (16) and tighten it with
the piston nut (19) according to the torque value specified in
Appendix A.
(iii) Insert the lock washer (17) and then secure the piston nut using
the lock nut (18). Bend the lips of the lock washer and secure the
lock nut from loosening.
(iv) Replace new O-rings in the head end cover (3), rod end cover (4)
and seal casing (7). Replace new oil seals (9) into the seal casing
(7).
(v) Insert the assembled piston rod into the cylinder tube (2) and
replace the head end cover (3) and the rod end cover (4) onto the
cylinder tube.
(vi) Insert the tie rods (15) through the end covers (3 and 4) and then
install the washers (14) and nuts (13). Tighten the four nuts
sequentially to the torque values specified in Appendix A. Secure
the nuts by lock wire (12).
(vii) Replace the bushing (8), seal casing (7) and seal cover (6) and
secure them to the rod end cover using the securing fasteners.
Replace the assembled hydraulic cylinder and other actuator
components to the hydraulic actuator. Reassemble them as per the
reverse sequence to that followed for disassembly in Steps 1 to 10.
No additional information is required.
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Mitsubishi
5-47
Chapter 5
MAIN COVER
A
MANIFOLD
PIPE BLOCK
19
DUMP VALVE
ASSEMBLY
3
13 12 11 10 9 8 7 6 5 4 3 2 1
CLEVIS
7
SERVO VALVE
ASSEMBLY
3
HYDRAULIC CYLINDER
A-A
FILTER
VALVE BLOCK
8
A
4
1
2
3
4
5
6
7
8
9
19
COVER ASSEMBLY
Rev.001
ACCUMULATOR
MM-M05.02
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FIGURE 5-6

Mitsubishi
CYLINDER BODY
PIPE BLOCK
VALVE BLOCK
ACCUMULATOR
FILTER
DUMP VALVE
SERVO VALVE
COVER ASSEMBLY
MANIFOLD
CLEVIS
GENERAL DISASSEMBLY SEQUENCE FOR A STEAM ADMISSION VALVE ACTUATOR
5-48
Chapter 5
16
18
19
11
20
ROD END
HEAD END
17
21
11
16
14 13
11
HEAD END
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
CYLINDER TUBE
HEAD END COVER
ROD END COVER
SCREW
SEAL COVER
SEAL CASING
BUSHING
OIL SEAL
DUST SEAL
"O" RING
LOCK WIRE
NUT
WASHER
TIE ROD
PISTON ROD
LOCK WASHER
LOCK NUT
PISTON NUT
PISTON
PISTON RING
11
12
13
13
10
ROD END
14
15
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FIGURE 5-7

Mitsubishi
GENERAL DISASSEMBLY SEQUENCE FOR A STEAM ADMISSION VALVE ACTUATOR HYDRAULIC CYLINDER
5-49
Chapter-6
C h a p t er
6 Corrective Maintenance
Corrective maintenance is the repair or replacement work undertaken for sudden failure of
any part or component of the equipment. Though a well planned preventive maintenance
program tries to minimize the probability of occurrence of sudden failure of equipment,
provision for attending these unscheduled maintenance requirements is to be made.
Corrective maintenance work is to be given priority depending on the seriousness of the
problem faced and the impact on plant operations. The schedule for repair of any
equipment should be carefully planned to keep outage time to a minimum.
During such repair or replacement work, an inspection is to be carefully conducted to
determine why the equipment has failed. Good corrective maintenance requires, not only
the quick restoration of the failed equipment back into service but also demands every
effort to identify and record the root cause of the failure. The inspection results can be of
significant help in exploring the exact reason for the failure. The findings, along with
possible rectification proposals, are to be used as a feedback to update the preventive
maintenance procedures.
6.1
Prerequisites
The necessary prerequisites for the corrective maintenance of the turbine steam
admission valves, actuators and servo-systems are as follows:
a)
Scheduling
Unlike preventive maintenance, scheduling activity only starts after failure of
the equipment. Depending on the severity of the problem, the importance of
the service provided by the failed equipment and availability of manpower to
attend to the problem, a contingency schedule is to be prepared to solve the
problem at the earliest opportunity. The schedule should clearly indicate the
critical path activity and assign the priority for different parallel activities.
Finally, once the schedule is agreed, strict adherence to it is to be maintained
to ensure timely completion of the maintenance activity.
b)
Departmental Interface/Notification
Refer to Section 4.1.2, Departmental Interface/Notification.
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c)
Isolation of Equipment
Refer to Section 4.1.3, Isolation of Equipment.
d)
Safety Precautions
Refer to Section 4.1.4, Safety Precautions.

Mitsubishi
6-1
Chapter-6
6.2
Preparation
a)
Parts, Tools and Equipment

Refer to Subsection 4.2.1 a), Parts, Tools and Equipment.
b)
Documentation
Refer to Subsection 4.2.1 b), Documentation.
6.3
Troubleshooting
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This section provides information about carrying out troubleshooting and servicing
for the turbine steam admission valves, actuators and servo-systems, pertaining to
mechanical maintenance staff. Tables of Faults, Possible Causes and Remedies
have been provided to assist in troubleshooting by qualified users. If any new kind
of problem is encountered which is not listed in the following table, contact the
manufacturer for assistance.

Mitsubishi
6-2
Chapter-6
TABLE 6-1
TROUBLESHOOTING - STEAM ADMISSION VALVES AND

ACTUATORS
Fault
External leakage of steam
from valve stem gland
External leakage of steam

from valve bonnet flange
Possible Cause
Remedy
Gland steam pressure (flow) increased due to:
stem-bushing seal
Repair or replace defective

components
gland condenser (GC) vacuum low
Raise GC vacuum
Check and repair defective
GSC vent fan
back seat is passing steam
Mating-lap the back seat
Flange bolts tightening insufficient
Retighten bolts
Flange gasket is faulty
Replace gasket
Increased bushing clearance
Replace defective bushing
Valve body/bonnet flange face is deformed
Correct by machining
External leakage of oil from

hydraulic cylinder
Drain line is clogged
Check the drain line
Oil seal packing is faulty
Replace oil seal packing
Valve movement is
sluggish/stuck
Scale or debris deposited on stem-bushing

clearance
Remove scale by
overhauling
Stem is bent
Replace defective stem
Dump valve does not open
Dump valve seat is leaking
Disassemble and rectify

dump valve
HP fluid to dump valve is

closed
Filter is clogged
Clean or replace the filter
Valve does not close
LVDT is faulty
Check LVDT electrically
Closing spring is faulty or stuck
Check by overhauling
LVDT feedback is faulty
Loose connection or
interference, check visually
and repair
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Hysteresis increased
(Excepting RSV)

Mitsubishi
6-3
Chapter 7
Recommended Lubrication
C h a p t er
7 Recommended Lubrication
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There is no lubrication requirement for the turbine steam admission valves beyond those
given in the relevant reassembly procedure (as a part of Chapter 5).

Mitsubishi
7-1
Appendix A
A p p en d i x
A Torque Chart
TABLE A-1
TORQUE CHART
Description
Tightening Torque
Main stop valve:

Spring guide stem (20) to stem (11) connection
25 kg-m
Plug (18) in the valve stem
4 kg-m
Governing valve:
Valve stem (2) to special nut (16) joint
Upper stem bushing bolt (15)
Connecting rod (22) to knuckle (40) joint
92 kg-m
50.8 kg-m
92 kg-m
Interceptor valve:
Valve stem (20) to cross-head (26) connection
23 kg-m
Actuator piston rod (43) to cross-head (26) connection
23 kg-m
MSV Actuator:
Hydraulic cylinder tie rods
Piston nut
9 ~ 11 ton
26 kg-m
GV Actuator:
Piston nut
25.5 ~ 28 ton
180 kg-m
RSV Actuator:
13 ~ 16 ton
Piston nut
72~ 88 kg-m
ICV Actuator:
14 ~ 17 ton
105 ~ 128 kg-m
Seal casing bolts
15.8 ~ 17.6 kg-m
MM-M05.02
Rev.001
Piston nut

Mitsubishi
A-1
Appendix A
TABLE A-2
CONTROLLED TIGHTENING (Refer also to Appendix F)
Main Stop Valve Figure 2-6

Bolt
Free
Length
(mm)
Nut First
Torque
(kg m)
Nut
Turn
Angle
()
Nut
Torque
(kg. m)
Bolt
Stretch
(mm)
Equipment
Part
No
Bonnet Studs
23
3 x 555
410.2
82
152.8
0.8
Spring
Housing
Studs
38
1 x 145
79.6
27.2
25
66.0
Bolt
Free
Length
(mm)
Nut First
Torque
(kg m)
Nut
Turn
Angle
()
Nut
Torque
(kg. m)
Bolt
Stretch
(mm)
325
68.6
120
0.63
103.4
27.2
31
66.0
Size
Governing Valve Figure 2-9
Equipment
Part
No
Bonnet Studs
88
21/2 x
455
Spring
Housing
Studs
38
1 x 170
Size
Reheat Stop Valve Figure 2-14

Equipment
Part
No
Size
Bolt Free
Length
(mm)
Nut First
Torque
(kg.m)
Nut Turn
Angle ()
Nut Tightening
Torque
(kg.m)
Valve cover
studs
11/2 x 365
278.1
41.1
85
215.8
Support
studs
12
11/4 x 215
137.8
34.3
46
134.8
Side cover
studs
11/4 x 215
137.8
34.3
46
134.8
Bolt Free
Length
(mm)
Nut First
Torque
(kg m)
Nut Turn
Angle ()
Nut Torque
(kg. m)
274.8
40.9
83
215.8
Interceptor Valve Figure 2-17
Bonnet studs
15
Size
11 / 2 x
365
MM-M05.02
Rev.001
Equipment
Part
No

Mitsubishi
A-2
Appendix B
A p p en d i x
MM-M05.02
Rev.001
Recommended
Spare Parts

Mitsubishi
B-1
Appendix B
TABLE B-1
MM-M05.02
Rev.001
Supplier
Name
Eqt. ID No.
Parts ID
RECOMMENDED LIST OF STRATEGIC SPARE PARTS
Parts Description
Installed Qty.
Eqt.
Description
Manuf.
Parts No.
Per each eqt.
Total Plant
Strategic Spare
Qty.
MHI
03MAA02AA1
Bushing
Main Stop Valve
MHI
03MAA02AA1
Bonnet gasket
Main Stop Valve
MHI
03MAA02AA1
Main valve
Main Stop Valve
MHI
03MAA02AA1
Valve stem
Main Stop Valve
MHI
03MAA02AA1
Plug
Main Stop Valve
MHI
03MAA02AA1
Pilot valve
Main Stop Valve
MHI
03MAA02AA1
Valve nut
Main Stop Valve
MHI
03MAA02AA1
Spring support
Main Stop Valve
10
MHI
03MAA02AA1
Spring
Main Stop Valve
15
MHI
03MAA02AA1
10
Bushing
Main Stop Valve
16
MHI
03MAA02AA1
11
Bushing
Main Stop Valve
17
MHI
03MAA02AA1
12
Hex. Socket head bolt
Main Stop Valve
19
12
MHI
03MAA02AA1
13
Spring guide rod
Main Stop Valve
20
MHI
03MAA02AA1
14
Pin
Main Stop Valve
21
MHI
03MAA02AA1
15
Liner
Main Stop Valve
22
MHI
03MAA02AA1
16
Stud bolt
Main Stop Valve
23
16
MHI
03MAA02AA1
17
Cap nut
Main Stop Valve
24
16
MHI
03MAA02AA1
18
Spherical washer
Main Stop Valve
25
16
MHI
03MAA02AA1
19
Spherical washer
Main Stop Valve
26
16
MHI
03MAA02AA1
20
Stud bolt
Main Stop Valve
27
18
36

Mitsubishi
B-2
Appendix B

TABLE B-1
Parts ID
Parts Description
Eqt.
Description
Installed Qty.
Manuf.
Parts No.
Per each eqt.
Total Plant
Strategic Spare
Qty.
MHI
03MAA02AA1
21
Cap nut
Main Stop Valve
28
18
36
MHI
03MAA02AA1
22
Spherical washer
Main Stop Valve
29
18
36
MHI
03MAA02AA1
23
Spherical washer
Main Stop Valve
30
18
36
MHI
03MAA02AA1
24
Plug
Main Stop Valve
31
18
36
MHI
03MAA02AA1
25
Plug
Main Stop Valve
32
18
36
MHI
03MAA02AA1
26
Bushing
Main Stop Valve
71
MHI
03MAA02AA1
27
Valve set
Main Stop Valve
MHI
03MAA03AA1
Stud bolt
Governing Valve
12
48
12
MHI
03MAA03AA1
Cap nut
Governing Valve
12
48
12
MHI
03MAA03AA1
Spherical washer
Governing Valve
12
48
12
MHI
03MAA03AA1
Spherical washer
Governing Valve
12
48
12
MHI
03MAA03AA1
Bonnet gasket
Governing Valve
13
MHI
03MAA03AA1
Valve
Governing Valve
14
MHI
03MAA03AA1
Valve seat
Governing Valve
15
MHI
03MAA03AA1
Pin
Governing Valve
16
16
MHI
03MAA03AA1
Valve stem
Governing Valve
17
Rev.001
Eqt. ID No.
MHI
03MAA03AA1
10
Bushing
Governing Valve
18
MHI
03MAA03AA1
11
Bushing
Governing Valve
19
MM-M05.02
Supplier
Name
MHI
03MAA03AA1
12
Hex. socket head bolt
Governing Valve
20
24

Mitsubishi
B-3
Appendix B

TABLE B-1
Parts ID
Parts Description
Eqt.
Description
Installed Qty.
Manuf.
Parts No.
Per each eqt.
Total Plant
Strategic Spare
Qty.
MHI
03MAA03AA1
13
Stud bolt
Governing Valve
29
36
MHI
03MAA03AA1
14
Nut
Governing Valve
30
36
MHI
03MAA03AA1
15
Spherical washer
Governing Valve
31
36
MHI
03MAA03AA1
16
Spherical washer
Governing Valve
32
36
MHI
03MAA03AA1
17
Governing Valve
38
16
MHI
03MAA03AA1
18
Pin
Governing Valve
39
MHI
03MAA03AA1
19
Pin
Governing Valve
43
MHI
03MAB02AA1
Valve
Reheat Stop Valve
MHI
03MAB02AA1
Valve stem
Reheat Stop Valve
MHI
03MAB02AA1
Bushing
Reheat Stop Valve
MHI
03MAB02AA1
Bushing
Reheat Stop Valve
MHI
03MAB02AA1
Bushing
Reheat Stop Valve
MHI
03MAB02AA1
Bushing
Reheat Stop Valve
10
MHI
03MAB02AA1
Shoulder ring
Reheat Stop Valve
20
MHI
03MAB02AA1
Retaining ring
Reheat Stop Valve
21
MHI
03MAB02AA1
Key
Reheat Stop Valve
28
Rev.001
Eqt. ID No.
MHI
03MAB02AA1
10
Bonnet gasket
Reheat Stop Valve
34
MHI
03MAB02AA1
11
Side cover gasket
Reheat Stop Valve
35
MM-M05.02
Supplier
Name
MHI
03MAB02AA1
12
Nut
Reheat Stop Valve
36

Mitsubishi
B-4
Appendix B

TABLE B-1
Eqt. ID No.
Parts ID
Parts Description
Installed Qty.
Eqt.
Description
Manuf.
Parts No.
Per each eqt.
Total Plant
Strategic Spare
Qty.
MHI
03MAB02AA1
13
Pin
Reheat Stop Valve
37
MHI
03MAB02AA1
14
Stud bolt
Reheat Stop Valve
39
24
48
12
MHI
03MAB02AA1
15
Stud bolt
Reheat Stop Valve
40
12
24
MHI
03MAB02AA1
16
Cap nut
Reheat Stop Valve
41
24
48
12
MHI
03MAB02AA1
17
Nut
Reheat Stop Valve
42
24
48
12
MHI
03MAB02AA1
18
Stud bolt
Reheat Stop Valve
43
12
24
MHI
03MAB02AA1
19
Spherical washer
Reheat Stop Valve
44
24
48
12
MHI
03MAB02AA1
20
Spherical washer
Reheat Stop Valve
45
24
48
12
MHI
03MAB02AA1
21
Spherical washer
Reheat Stop Valve
46
24
48
12
MHI
03MAB02AA1
22
Spherical washer
Reheat Stop Valve
47
24
48
12
MHI
03MAB02AA1
23
Disc spring
Reheat Stop Valve
55
16
MHI
03MAB02AA1
24
Reheat Stop Valve
58
12
24
MHI
03MAB02AA1
25
Spring
Reheat Stop Valve
66
MHI
03MAB02AA1
26
Bearing
Reheat Stop Valve
73
MHI
03MAB02AA1
27
Plug
Reheat Stop Valve
74
MHI
03MAB02AA1
28
Plug
Reheat Stop Valve
76
36
72
18
MHI
03MAB02AA1
29
Plug
Reheat Stop Valve
77
12
24
MHI
03MAB02AA1
30
Reheat Stop Valve
78
MM-M05.02
Rev.001
Supplier
Name

Mitsubishi
B-5
Appendix B

TABLE B-1
Eqt. ID No.
Parts ID
Parts Description
Installed Qty.
Eqt.
Description
Manuf.
Parts No.
Per each eqt.
Total Plant
Strategic Spare
Qty.
MHI
03MAB03AA1
Valve stem
Interceptor Valve
MHI
03MAB03AA1
Bushing
Interceptor Valve
MHI
03MAB03AA1
Bushing
Interceptor Valve
MHI
03MAB03AA1
Retainer
Interceptor Valve
MHI
03MAB03AA1
Interceptor Valve
16
MHI
03MAB03AA1
Pressure seal ring
Interceptor Valve
MHI
03MAB03AA1
Stud bolt
Interceptor Valve
17
32
MHI
03MAB03AA1
Stud bolt
Interceptor Valve
18
28
112
28
MHI
03MAB03AA1
Nut
Interceptor Valve
19
28
112
28
MHI
03MAB03AA1
10
Spherical washer
Interceptor Valve
20
28
112
28
MHI
03MAB03AA1
11
Spherical washer
Interceptor Valve
21
28
112
28
MHI
03MAB03AA1
12
Spherical washer
Interceptor Valve
22
32
MHI
03MAB03AA1
13
Spherical washer
Interceptor Valve
23
32
MHI
03MAB03AA1
14
Liner
Interceptor Valve
26
MHI
03MAB03AA1
15
Screw
Interceptor Valve
29
MHI
03MAB03AA1
16
Screw
Interceptor Valve
30
MHI
03MAB03AA1
17
Nut
Interceptor Valve
36
32
MHI
03MAB03AA1
18
Main valve assembly
Interceptor Valve
MM-M05.02
Rev.001
Supplier
Name

Mitsubishi
B-6
Appendix B

TABLE B-1
Supplier
Name
Eqt. ID No.
MHI
03MAA02AE101
03MAA02AE102
MHI
03MAA03AE101
03MAA03AE102
03MAA03AE103
03MAA03AE104
MHI
03MAB02AE101
03MAB02AE102
MHI
03MAB03AE101
03MAB03AE102
MM-M05.02
Rev.001
03MAB03AE103
03MAB03AE104
Parts ID

Eqt.
Description
Manuf.
Parts No.
Installed Qty.
Per each eqt.
Total Plant
Strategic Spare
Qty.
GV actuator
RSV actuator
ICV actuator
Parts Description
MSV actuator
EH oil system
MHI
03MAB04AA101
03MAB04AA102
Trip solenoid valve
MHI
03MAY03AA502
Emergency piston valve
MHI
03MAY03AA502
1/4 Stop valve
12
12
MHI
03MAY03AA502
3/8 Check valve
32
32
MHI
03MAY03AA502
Servo valve
10
10
MHI
03MAY03AA502
OPC solenoid valve
MHI
03MAY03AA502
O ring (AS568-8)
16
16
MHI
03MAY03AA502
O ring (AS568-12)
MHI
03MAY03AA502
RSV test solenoid valve
MHI
03MAY03AA502
O ring (AS568-8)

Mitsubishi
B-7
Appendix B

TABLE B-1
Supplier
Name
Eqt. ID No.
Parts ID
Parts Description
Eqt.
Description
Manuf.
Parts No.
Installed Qty.
Per each eqt.
Total Plant
Strategic Spare
Qty.
03MAY03AA502
O ring (AS568-12)
MHI
03MAY03AA502
Filter element
12
12
12
MHI
03MAY03AA502
Back up ring
12
12
12
MHI
03MAY03AA502
O ring (AS568-214)
12
12
12
MHI
03MAY03AA502
O ring (C60)
12
12
12
MHI
03MAY03AA502
O ring (P16)
36
36
36
MM-M05.02
Rev.001
MHI

Mitsubishi
B-8
Appendix C
A p p en d i x
MM-M05.02
Rev.001
C Special Tools

Mitsubishi
C-1
MM-M05.02
Rev.001
Appendix C
FIGURE C-1
Mitsubishi
SPECIAL TOOLS LIST
C-2
Appendix D
A p p en d i x
D Coupling Alignment
MM-M05.02
Rev.001
Coupling alignment information is not applicable to this equipment.

Mitsubishi
D-1
Appendix E
Applicable
E Reference Drawings
MM-M05.02
Rev.001
A p p en d i x

Mitsubishi
E-1
MM-M05.02
Rev.001
Appendix E
MPTD-3-1111
FIGURE E-1

Mitsubishi
MAIN STOP VALVE ASSEMBLY (1/3)
E-2
MM-M05.02
Rev.001
Appendix E
MPTD-3-1112

Mitsubishi
FIGURE E-2
E-3
MM-M05.02
Rev.001
Appendix E
MPTD-3-1113

Mitsubishi
FIGURE E-3
E-4
MM-M05.02
Rev.001
Appendix E
MPTD-3-1114

Mitsubishi
FIGURE E-4
GOVERNING VALVE ASSEMBLY (1/3)
E-5
MM-M05.02
Rev.001
Appendix E
MPTD-3-1115

Mitsubishi
FIGURE E-5
E-6
MM-M05.02
Rev.001
Appendix E
MPTD-3-1116

Mitsubishi
FIGURE E-6
E-7
MM-M05.02
Rev.001
Appendix E
MPTD-3-1117

Mitsubishi
FIGURE E-7
REHEAT STOP VALVE ASSEMBLY (1/3)
E-8
MM-M05.02
Rev.001
Appendix E
MPTD-3-1118

Mitsubishi
FIGURE E-8
E-9
MM-M05.02
Rev.001
Appendix E
MPTD-3-1119

Mitsubishi
FIGURE E-9
E-10
MM-M05.02
Rev.001
Appendix E
MPTD-3-1120

Mitsubishi
FIGURE E-10
INTERCEPTOR VALVE ASSEMBLY (1/2)
E-11
MM-M05.02
Rev.001
Appendix E
MPTD-3-1121

Mitsubishi
FIGURE E-11
INTERCEPTOR VALVE ASSEMBLY (2/2)
E-12
MM-M05.02
Rev.001
Appendix E
MPTD-3-1122

Mitsubishi
FIGURE E-12
MSV ACTUATOR ASSEMBLY (1/2)
E-13
MM-M05.02
Rev.001
Appendix E
MPTD-3-1122

Mitsubishi
FIGURE E-13
MSV ACTUATOR ASSEMBLY (2/2)
E-14
MM-M05.02
Rev.001
Appendix E
MPTD-3-1124

Mitsubishi
FIGURE E-14
GV ACTUATOR ASSEMBLY (1/2)
E-15
MM-M05.02
Rev.001
Appendix E
MPTD-3-1125

Mitsubishi
FIGURE E-15
GV ACTUATOR ASSEMBLY 2/2
E-16
MM-M05.02
Rev.001
Appendix E
MPTD-3-1126

Mitsubishi
FIGURE E-16
RSV ACTUATOR ASSEMBLY 1/2
E-17
MM-M05.02
Rev.001
Appendix E
MPTD-3-1127

Mitsubishi
FIGURE E-17
RSV ACTUATOR ASSEMBLY 2/2
E-18
MM-M05.02
Rev.001
Appendix E
MPTD-3-1128

Mitsubishi
FIGURE E-18
ICV ACTUATOR ASSEMBLY 1/2
E-19
MM-M05.02
Rev.001
Appendix E
MPTD-3-1129

Mitsubishi
FIGURE E-19
ICV ACTUATOR ASSEMBLY 2/2
E-20
Appendix
Controlled Tightening
F Procedures
A p p en d i x
DETERMINING BOLT STRETCH

Introduction
Alloy steel bolts and studs in the high pressure and/or high temperature flanges should be
tightened sufficiently to produce a definite amount of stretch as outlined in these instructions.
Amount of Stretch
The amount of stretch for alloy steel bolts or studs should be determined in accordance with the
following table:
TABLE F-1
STRETCH FOR ALLOY STEEL BOLTS OR STUDS

Required Initial Stress
(kg/mm2)
Amount of Stretch per

1 mm of Free Length
(mm)
JIS-SCM435
Equivalent material:
SAE413 or AISI14137
28
0.0013
W-10705BU
AISI616, Type 422
32
0.0015
W-15106FD
AISI690, Refractaloy 26, M8B
42
0.00195
Bolt Material
Free Length
MM-M05.02
Rev.001
The free length of a stud is the thickness of the flange from joint face to spot facing, plus one stud
diameter and washer thickness (if washers are used). The free length of a bolt extending through
both flanges is the thickness of both flanges between spot facings, plus one bolt diameter and
washer thicknesses (if washers are used).

Mitsubishi
F-1
Appendix
Equivalent Nut Rotation Angle

For any given application the calculated amount of stretch can be translated into an equivalent nut
rotation angle, provided that the number of threads per inch, or TPI of the fasteners is known.
For these applications, bolt diameters between 50 mm and 112 mm have 8 TPI, and bolt
diameters between 125 mm and 150 mm have 6 TPI
For example, if the nut of a 125 mm diameter bolt is turned through 36, the resulting stretch will
be 25 mm (metric equivalent of one inch) divided by 6 (number of TPI) and multiplied by 10% (the
percentage of a full turn applied).
Lubrication
The threads of bolts, studs and bearing faces of nuts should be well lubricated with a
recommended, anti-seize compound (N-5000) to reduce friction and to avoid thread seizure in
high temperature service.
Stretching
The larger size bolts and studs are provided with holes in their center for stretching by means of
electric heating elements. Smaller bolts and studs must be stretched by wrenching. It is preferable
to torque these in accordance with the following table:
TABLE F-2
NOMINAL DIAMETER OF BOLT VERSUS TIGHTENING TORQUE
Bolt material
2
Required stress kg/mm
SCM435
10705BU
15106FD
28
32
42
Torque
Inch
mm
kg/m
(12.7)
5.4
6.2
8.1
(15.9)
10.9
12.5
16.3
(19.1)
18.2
20.8
27.0
(22.2)
29.2
33.4
43.4
(25.4)
44.5
50.8
66.0
(28.6)
64.5
73.7
95.8
(31.8)
90.7
103.7
134.8
(34.9)
123.4
141.0
183.3
(38.1)
145.3
166.0
215.8
(41.3)
199.5
228.0
296.4
(44.5)
272.1
311.0
404.3
(47.6)
363.1
415.0
539.5
(50.8)
399.0
456.0
592.8
MM-M05.02
Rev.001
Bolt Diameter

Mitsubishi
F-2
Appendix
TIGHTENING LARGE BOLTS AND STUDS WITH HEATING ELEMENTS

1
Determine the required stretch.
Lubricate threads and face of nuts with anti-seize compound.
Run on the nuts to ensure freedom of thread movement.
Clean the bottom of the stud hole with compressed air.
Use a rod with a piece of cloth (smeared with a small amount of clean grease) securely
fastened to the end, to swab the stud hole clean.
Tighten all nuts in symmetry with a 68 kg m (Nut First Torque) by wrench.
Measure the stud or bolt, with the nut loose, using a micrometer and extension rod.
Obtain the required nut turn from the chart (Appendix A).
Use a protractor to indicate the required nut rotation and mark with a piece of chalk.
10
Heat the studs in accordance with the following instructions (Bolt Heater Instructions).
11
Rotate the nut by the calculated amount as soon as the stud has elongated.
12
Allow the stud or bolt to cool to the same temperature as in Step 6 above and clean the
bottom of the heater hole as in Step 5 above.
13
Measure the stud or bolt to see if the required stretch has been obtained (tolerance 10%).
14
Repeat Steps 5 to 13 above until the required stretch (10%) has been obtained.
BOLT HEATER INSTRUCTIONS

The heaters are of the insertion type, consisting of a heating element in a stainless steel sheath. If
a heater becomes deformed, its operation is not impaired as long as actual contact does not occur
between the heating element and the sheath.
The heater may be used with either AC or DC current in conjunction with the protection of fuses or
circuit breakers and adequate wiring to carry the current demand. When used with DC current, the
connector provided is not to be used as an interrupting device. It is also desirable that neither side
of the circuit be grounded. Absence of a ground reduces the likelihood of a short-circuit on a
heater. It is recommended that the heaters be used until they actually fail in service.
MM-M05.02
Rev.001
No attempt should be made to protect any part of the heater surface by wrapping it with asbestos
or other insulating material since this will cause overheating and result in a damaged coil.

Mitsubishi
F-3
Appendix
Precautions
a)
Bolt heaters are electrical devices capable of causing electrical shock if improperly used.
b)
Touching an energized or recently de-energized heater can cause serious burns.
c)
Store bolt heaters in a vertical position. Do not store the heater on its side while hot to
prevent deformation of the heater.
d)
Insert the heater into the bolt prior to energizing.
e)
A blackened heater is an indication that lubricant was present in the last stud in which the
heater was energized. Any blackened heater should be heated in the open air until it has
burned clean and then the debris brushed off.
Procedure
Insert the heater into every third bolt using a wooden handle.
Use a pipe spacer as required to keep the heater from bending when hot.
Energize heater (for 15 minutes maximum) until nut can be removed from the stud.
De-energize heaters and allow them to cool prior to removing them.
MM-M05.02
Rev.001

Mitsubishi
F-4
Appendix G
Valve Parts Removal

G Pr o c e d u r e D r a w i n g
MM-M05.02
Rev.001
A p p en d i x

Mitsubishi
G-1
MM-M05.02
Rev.001
Appendix G
MPTD-4-1077
FIGURE G-1

Mitsubishi
REMOVAL OF MSV ACTUATOR
G-2
MM-M05.02
Rev.001
Appendix G
FIGURE G-2

Mitsubishi
REMOVAL OF MSV SPRING HOUSING
G-3
MM-M05.02
Rev.001
Appendix G
FIGURE G-3
Mitsubishi
REMOVAL OF MSV BONNET
G-4
MM-M05.02
Rev.001
Appendix G
M P TD -4-1080
FIGURE G-4

Mitsubishi
REMOVAL OF GV ACTUATOR
G-5
MM-M05.02
Rev.001
Appendix G
S ID E V IE W
F R O N T V IE W
M P T D -4-1081
FIGURE G-5

Mitsubishi
REMOVAL OF GV SPRING HOUSING
G-6
MM-M05.02
Rev.001
Appendix G
MPTD-4-1082
FIGURE G-6

Mitsubishi
REMOVAL OF GV BONNET
G-7
Appendix G
MM-M05.02
Rev.001
MPTD-4-1083
FIGURE G-7
Mitsubishi
REMOVAL OF RSV COVER AND TRIP PILOT VALVE
G-8
Appendix G
MM-M05.02
Rev.001
MPTD-4-1084
FIGURE G-8

Mitsubishi
REMOVAL OF RSV ACTUATOR
G-9
MM-M05.02
Rev.001
Appendix G
M P TD -4-1085
FIGURE G-9

Mitsubishi
REMOVAL OF ICV ACTUATOR
G-10
MM-M05.02
Rev.001
Appendix G
M PTD-4-1086
FIGURE G-10

Mitsubishi
REMOVAL OF ICV SPRING HOUSING
G-11
MM-M05.02
Rev.001
Appendix G
MPTD-4-1087
FIGURE G-11

Mitsubishi
REMOVAL OF ICV BONNET
G-12
Appendix H
Ultrasonic Cleaning
H Procedure
A p p en d i x
Ultrasonic cleaning is a very effective method of cleaning filter elements, but results depend
greatly on the type of equipment used, and type of cleaners used for ultrasonic cleaning. There
are many cleaners available for use in ultrasonic cleaning, some of which are very effective for
cleaning filters, while others are completely unsatisfactory. If ultrasonic equipment is available, it
should be tried, since it is possible that a simple cleaning procedure using no strong chemical will
do an effective job of cleaning with ultrasonics. With any ultrasonic equipment, be sure to follow
the manufacturers instruction in regards to maximum operating temperature, which is usually
80C ~ 85C.
General Ultrasonic Cleaning Procedure:

1. Close inlet valve to the filter, open the vent and drain the unit completely. Remove the filter
elements from the empty housing.
2. Immerse the element in ultrasonic bath of hot alkaline solution for at least one-half hour
(time may vary. i.e. Grade 20 material with larger pore sizes cleans faster than grade 5
material). Rotate cylinder during cleaning.
3. Rinse with clean water (preferably distilled) for five minutes.
4. Blow out or dry in air.
5. Store in clean dust-free container or reinstall in filter housing.
Note
There are many fluids that can be used for ultrasonic cleaning. Most
manufacturers of chlorinated cleaning agents include a neutral inhibitor to
prevent the formation of hydrochloric acid when mixed with water. Ordinary
applications can use Oakite rustripper at 65C.
Note
Do not use an acid as the cleaning solution in an ultrasonic cleaner under any
circumstances.
MM-M05.02
Rev.001
Experience has shown that in some filter applications with fluids of an oily nature, a deposit will be
left over the filter surface which prevents effective cleaning. In these cases a vapour degreasing
prior to the cleaning procedures is recommended.

Mitsubishi
H-1

MM M05 4

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Project Dwg. No: G101-25-1700.

Steam Admission Valves

Steam Admission Valves Maintenance

Be sure to read this manual.

Disassembly and Reassembly

Feature of the Steam Admission Valves Safety 1-1

Warnings Description 1-2

Definitions of Serious Injury, Minor Injury, Serious

Hazard Warning Label 1-5

Hazard Area 1-7

Risk Assessment Standard 1-8

Safety Measures 1-10

Work Permit System (Lockout/Tagout) 1-10

General Cautions on Personnel in Working Area 1-11

1.4.2.1 Caution against Rotating Equipment 1-11

1.4.2.9 Cautions against Lifting Heavy Object 1-16

1.4.2.8 Cautions against Lack of Oxygen 1-15

1.4.2.11Cautions using Fork Lift 1-16

1.4.2.10Cautions against Sharp Objects 1-16

Steam Admission Valves

Safety (Continued from previous page)

Emergency Measure 1-19

Evacuation on Emergency Case 1-19

1.5.1.1 Evacuation Route 1-19

Fire Accident 1-21

Explosion Accident 1-22

Qualification and Training 1-23

Overview of Turbine Steam Admission Valves

Construction and Arrangement

HP Turbine Steam Chest and Steam Admission

IP Turbine Steam Admission Valve Assemblies

Steam Admission Valve Control Oil System

Preventive Maintenance _____________

Steam Admission Valves

Preventive Maintenance (continued) ______

Inspection and Maintenance

Annual Outage Maintenance

Inspection and Maintenance

Disassembly and Reassembly ________

Disassembly and Reassembly of Main Stop Valve

Disassembly and Reassembly of Governing Valve

Disassembly and Reassembly of Reheat Stop Valve

Disassembly and Reassembly of Interceptor Valve

Disassembly and Reassembly of Steam Admission

Corrective Maintenance _____________

Recommended Lubrication __________

Torque Chart A-1

Recommended Spare Parts B-1

Special Tools C-1

Coupling Alignment D-1

Applicable Reference Drawings E-1

Controlled Tightening ProceduresF-1

Valve Parts Removal Procedure Drawings G-1

Ultrasonic Cleaning H-1

Steam Admission Valves

Types of Hazard Warning Label

Mapping of Hazard Areas

Isometric View of the Turbine and Steam

HP Turbine Steam Admission Valves Assembly

IP Turbine Steam Admission Valves Assembly

Cutaway View of Steam Chest and HP Turbine

Arrangement of Steam Chest Support

Sectional View of Main Stop Valve