Modernizing Critical Turbine Isolation Systems
TCB Industrial was tasked with the demolition, removal, and installation of three new large-diameter turbine shutoff valves as part of a major powerhouse modernization effort. The existing valves were original to the facility and had been installed prior to the concrete superstructure being poured, creating significant access and removal constraints.
Each new butterfly-style valve measured approximately 2,730 mm (107 inches) in diameter and required precise handling, alignment, and integration with new hydraulic and control systems.
Engineering Around Fixed Infrastructure
Because the powerhouse ceiling and surrounding concrete were constructed after the original valve installation, traditional removal methods were not feasible. TCB engineered custom jacking, rolling, and transport systems to safely extract the existing valves and position the new units within the constrained footprint.
This work required:
- Development of custom load paths
- Tight tolerance control during rolling operations
- Continuous verification of structural limits
All methods were engineered and sequenced to maintain safety while protecting surrounding civil structures.
Mechanical, Hydraulic, and Electrical Integration
In addition to valve replacement, TCB installed new high-pressure hydraulic power units (HPUs) and associated piping. Electrical and control interfaces were integrated to ensure reliable operation and monitoring.
The work was executed under active outage constraints and coordinated closely with operations and engineering stakeholders to maintain schedule discipline.
Outcome
The project was completed ahead of schedule and under budget. The upgraded shutoff valves significantly improved unit reliability and maintainability while reducing long-term operational risk.
This installation demonstrated TCB’s capability to deliver complex hydro-mechanical upgrades within legacy infrastructure environments.
