EGS overhaul three Ansaldo Valve Actuators

18th – 29th June 2012


British Sugar

The final elements to the British Sugar upgrade have been completed. This ultimate stage consisted of comprehensive functional testing of all elements to the set, emergency stop tests, overspeed trip testing and a final testing of the turbine onload.

The ProTech TPS was tested to ensure it functioned correctly. The TPS is a 2 out of 3 system in which there are three independent modules; if any two give the same value it results in a functional output. If one module fails therefore, the system can still function and an alert of the failed module will be issued. The correct functioning of the three dual MPUs was also tested to ensure all three read correctly with the turbine turning over an electric motor at 263 RPM.

We also tested the 505 overspeed trip and the mechanical overspeed trip. The CPC-II (Current to Pressure Converter) was the final module to be tested. It is wired to the 505 control that positions the steam inlet valve to desired position depending on speed and load. All data feeds back to the HMI enabling the status of equipment to be monitored.

Lastly we ensured a final testing of the turbine onload took place, which generated 8MW and exported 4MW to the National Grid. The final test was very successful and proved very stable.

Overhaul and service

Ansaldo Valve Actuators

Our customer, a specialist installer of steam turbine generator sets, approached us to have a selection of valve actuators overhauled and performance tested in order to improve the performance of the valves. Significant wear could be noted in addition to oil leakages which were limiting oil pressure by two bar.

We were sent three valves:

  • One HP Control Valve Actuator, for inspection of the glyde ring and cylinder bore.
  • A Main Steam Stop Valve Power Cylinder, which was showing signals of excessive wear in particular to the cylinder bore and piston.
  • An Oil/Air Relay Device – the customer was experiencing problems of air relay changeover and air escaping.

To overcome these challenges we replaced all seals which were designed and remanufactured due to being obsolete. All bores were also honed and we machined new bushings and piston rods where necessary.

The valves were tested hydraulically to the customer desired set points in addition to oil pressure.

Check out the photos of these valves pre and post overhaul to the right.


Governor Technician Steve recently overhauled a TG17E, an electric turbine governor. Unlike the TG, it doesn’t have a ballhead assembly, but rather a milliamp control. This was a routine overhaul in which all parts were cleaned, inspected for wear and replaced as necessary. All consumable parts were also replaced and the TGE tested to specification using a calibrated milliamp supply versus degrees output.

You can see a picture of the TGE to the right on test by Test Supervisor Ivor.


Governor Technician Chris overhauled one RE 1102V-4G-25L, high pressure governor of around 250 psi. The state of the governor was particularly dirty indicative of heavy engine oil contamination from the drive shaft oil seal.

Several key components had suffered notable wear. The rotor assembly was a 3G rotor, replaced with the metrics version 4G. The drive shaft was also replaced in addition to all consumable parts, gaskets and seals. The motor was also excessively worn and replaced.

The RE can be seen on test to the right.

EGS raise funds for Cry in the Dark

4th – 15th June 2012


This fortnight within the overhaul department Technicians Mick and Chris have overhauled two RE 1104A-3G governors for the RMAS Careful. These took place in the format of routine overhaul with all consumable and worn parts replaced as necessary.

See to the right a photo of one of the REs on test, one complete RE ready for decaling, in addition to a great photo of the RMAS Careful at Plymouth on the 25th May in 1995. For more images and information, see the Royal Maritime Auxiliary Service website here.

Upon completion of testing by technician Ivor, the REs will be sent  to be packed for shipping by Storeman Ian. Technicians Chris and Mick will then move onto the overhaul of two PG-PL governors.

This fortnight we have also supplied three UG40 actuators for Baku, Azerbaijan for a pipe laying vessel.


The work we are doing for British Sugar, which we showcased last fortnight, is almost complete. Technician Chris attended site to fit the CPC-II and complete all pipework. The original CPC bracket was in poor condition consisting of a plastic box which was worn and broken.

We designed and made a new bracket for the CPC-II which was moved back to make space for the new, much more robust bracket; far more suitable for the design.

Technicians Karl and Jon are onsite fitting the HMI and completing the final details; testing should take place Monday.


This Friday the 15th of June, some of the EGS team members will be baking sausage rolls and cakes to raise money for Cry in the Dark, a Colchester based charity that support children and families in Romania. For more information about Cry in the Dark, visit their website. We are also hoping to have a BBQ fundraising day later this summer.

EGB Proport governors overhauled for Ministry of Defence

May 21st – June 1st 2012


Following the completion of the sea trials mentioned in last fortnight’s post, the controls upgrade consisting of a 723 PLUS and PGA-EG triple redundant system per engine for an ocean research vessel, is fully complete. Chris, who accompanied engineers Jon and Karl to assist with the installation and in particular the new pipework, took some great photos during the project, which can be found to the right.

We are now working on the completion of the upgrade project for British Sugar. Friday the 25th May, engineers Jon, Karl and Chris attended site to record all information and measurements necessary to install the new 505panel and CPC-II system.

The requirements for the new system, conveyed to us by British Sugar consist of the removal of the existing Woodwood 505 governor system and its associated hydraulic pipework and valves, and replacing with the new generation of Woodwood 505 PLUS and CPCII mounted in purpose built panel. We will also be fitting a HMI505 view for remote control and monitoring.

The requirements of the project are as follows: load control, back pressure control , isochronous frequency control, run up and control of set speed prior to synchronisation, control of set speed for purposes of back synchronisation, inlet pressure control at the turbine governor controller, control panel to house all equipment controller, Bentley 3500 system, TMR overspeed system, steam chest temperatures, critical interlocks, dual redundant power supplies, clean earthing bar, trip protection key switch, retransmission of signals for DCS and terminal for all spare cores, HMI to view all temperatures, pressures, levels, vibration levels and speed indication and integral electronic overspeed protection with TMR functionality.


We have completed the Ansaldo steam turbine actuator overhaul that was briefly mentioned in last fortnight’s post. This took place in the form of a routine overhaul, major parts were replaced including new servo rod and new piston arrangement. The main case was rebored, rebuilt and calibrated to customer specification. The finished product was collected by the customer.

We are also working on the overhaul of two 13 ft lb EGB proport dial governors for the MOD for which it was necessary to replace the pilot valve bushing due to wear. To the right you can see several photos of the EGB job at various stages of the overhaul process.

Agents – Essex Governor Services Middle East and Asia

There are several overhaul projects taking place within the department for our agent Ian Skins; supply of a TG13 new unit to Singapore, two PGD governors and an urgent UG10D.

Furthermore, in line with our new website and rebrand, our agent Ian is working with New Zealand based web design agency Mogul on the development of his new site. Much like ours, a completely fresh approach is necessary. Ian is working with developer Anna on a simple but easy-to-use layout; this is due for completion towards the end of next month.