Collector Ring Machining

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During any turbine generator outage season we often receive an influx of calls to perform collector ring machining on various makes and models of generators.  It is critical to maintain as much brush to collector ring contact as possible, and machining the rings can make sure the surface is free from defects that may inhibit brush to ring contact.  The need for this machining is typically determined after the generator has been disassembled and inspected, making this service an emergent repair that needs to be performed within a time-sensitive window.  When these requests are received we typically request basic dimensional data and then provide a quick quotation for services.  Once approved, we immediately dispatch our qualified technicians to site along with specialized machining equipment.  This work is typically completed in 1-2 shifts, and the customer is able to continue forward without this service having any impact on the overall schedule.

 

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Gas Turbine Compressor Inspections

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We recently completed the inspection of a Westinghouse Combustion Turbine Compressor Section.  This inspection can be performed standalone, or is typically performed as part of a Major Inspection.  It is imperative that the compressor section is free from defects and has proper clearances to allow air to flow toward the combustion section as smoothly as possible as pressure increases.  Executing the proper inspection procedures and techniques is imperative to any good Compressor Section inspection.  Our technicians have been trained on inspection and repair techniques for most major industrial combustion turbine compressor types from various OEM makes and models.  The expertise of the technicians performing the inspection is critical to successful future operation of the equipment.

Crane Safety

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When PSG begins planning for an outage, we ask the customer for a Crane Safety Report complying with OSHA Regulation 29 CFR 1910.179. This is an OSHA compliance issue that PSG feels is well warranted. First, we have a commitment to our employees to keep them safe from harm.   A crane malfunction can easily injure, maim or even kill. Second, we have a commitment to our customers to do quality work in the time frame allotted per their work scope.  That means the overhead crane needs to be in perfect operational condition in order for PSG to perform the outage safely.  A crane malfunction can damage customer property and/or delay operations during repairs.

Crane safety reports fall into two categories: Frequent and Periodic. Frequent inspections are for cranes that have been idle for a period of 1 month or more, but less than 6 months. This usage pattern necessitates conformance with a minimum set of OSHA requirements. Periodic inspections are for cranes that have been idle for a period of over 6 months. These cranes must be inspected according to more stringent OSHA requirements. Note that the less often the crane is used, the more vital the inspection.

One critical inspection for all cranes is a test of the upper limit switch. This switch is designed to prevent the hook block assembly from contacting the drum assembly.  If the block contacts the drum, the hook and block will fall from the maximum height of the crane, dropping whatever load is on that hook. That is a very scary prospect.

To minimize this prospect, the crane operator should keep the block well clear of the limit switch in normal operation. It is a safety device NOT an operational device. And it is just one of the necessary safety requirements which must be verified with the Crane Safety Report.

Alstom STF Steam Turbines

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We perform all types of inspections on the legacy Alstom STF Steam Turbine Fleet.  Below is a photo of the IP Inner Casing being moved during a C Inspection.   We can perform A, B, and C inspections on the STF fleet, and many of our team members are former Alstom personnel that have the knowledge required to successfully execute these projects.  Please contact us for all of your STF steam turbine outage planning and execution needs.

Steam Turbine Rotor

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Another industrial steam turbine rotor prepped and ready to ship out for repairs. Our field teams do a fantastic job executing turnkey steam and gas turbine outages. Contact us today to help you plan for your next inspection.

Steam Turbine Major Inspection

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We’re lifting the LP upper half casing on a Westinghouse Steam Turbine.   Great attention to detail and planning is required to perform a safe, quality lift of this nature.  Nice job team!

Keeping the Electricity Flowing

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We have quite a few projects ongoing at the moment, even with current COVID-19 concerns.  Providing electricity to homes all across the country is vital to the well-being of the public, and it is our responsibility to continue on as we try to get through this together.  The men and women that are out in the field performing this work are making a sacrifice for all of us as the country continues to tighten restrictions on travel and access to everyday necessities.  We’d like to thank turbine maintenance personnel all across the World for what they are doing right now to keep electricity flowing – stay safe and healthy out there!

Welcome to the team Ralph Pederson!

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We would like to welcome Ralph Pederson to the PSG team! Ralph has joined our team as a Principal Steam Turbine Engineer and has a 40+ year background working in various central electric and steam power stations. He previously worked for Westinghouse as a service engineer, technical support contact, and salesperson. Ralph has held a position as a Senior Engineer with an aftermarket electric utility industry service organization. He has been a Senior Specialty Engineer at a 2-unit nuclear power station and has been a Turbine Coordinator for a large investor-owned utility. Ralph has also worked as a Director of Engineering/Technical Services for an aftermarket provider of turbine parts to power utilities. His extensive background in the power industry will be a tremendous asset to our team.

Ralph has a bachelor’s degree in Mechanical Engineering from the University of Grand Forks and has done extensive graduate work at Cardinal Stritch University. He has received ASME recognition of piping and pressure studies (ASME Section 3, ASME B31.1), Level Two Vibration Analysis certification, Nuclear Utility company training of Pressurized Water Reactor Power Plant, as well as specialized training on non-destructive inspection techniques. Ralph is a member of the American Society of Mechanical Engineers (ASME), American Society of Testing & Materials, and ASM International.

Welcome to the team Ralph, we’re all looking forward to working with you!

 

Safety Bulletin – Chainfalls and Come-Alongs

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by Shannon Scruggs, PSG Safety Director

The chainfall and come-along are two very common manual mechanical lifting devices. Both are designed to provide safety to those using them. But they must be used properly if they are to function safely. Remember the following precautions:

1.   Always use the proper capacity hoist for the job you are about to do, remembering that two people pulling on the hand chain will increase the amount you can physically lift but will not increase the capacity of the hoist you are using.

2.   Inspect the hoist before you begin to lift any load. Check the upper and lower hooks to see that they swivel properly and are in good shape. Check the inspection date on the hoist housing to ensure it has been inspected within the last 12 months.

3.   Inspect the full length of chain as much as possible, look for badly gouged, worn or defective links. Make a load test by lifting and lowering a load slightly. This will tell the operator if the unit is functioning properly.

4.   Stand completely clear of the load at all times. Allow no portion of your body or a fellow worker’s body under the load.

5.   Center the load under the hoist.

6.   Always properly seat the load in the hook.

7.   Proper care and handling make a safe hoist. Remember the hoist was designed to ease our burden, and carelessness not only endangers the operator, but in many cases, a valuable load. Keep the chain hoists free of dirt and foreign material. Store all hand chain hoists in a hanging position in a clean area.

8.   Do not attempt to “fix” a defective chainfall or come-along. Tag it as “defective” and have it returned to the toolroom for repair or disposal.

Treat the hoist properly, respect its limitations and it will work safely for a long time to come.

Remember: Hazard Awareness + Hazard Mitigation + Focus = Zero Injuries

Steam Turbine Low-Speed Balance

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Our Steam Path Repair facility in Pevely, Missouri has many steam turbine rotors that come through each and every year.  One of the services we offer to our customers after repairs have been performed is a low speed balance.  You can see the process in action here on a 3-bearing steam turbine rotor for a turbine that is rated at approximately 80MWs.