Outage Planning Services

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Pre-Outage Planning

A Customized Plan

Most power producers are short-staffed and do not have the time and sometimes the expertise to prepare a comprehensive outage plan and workscope.  That’s why we offer the option of providing our comprehensive Pre-Outage Planning Service independent of the award of the contract for inspection and repairs.

Our field project teams have the breadth of knowledge and experience to produce the highest quality planning product, with a workscope customized to your unit and its specific signature.

One of our qualified Technical Directors will visit your plant and prepare a customized report for your specific unit.  The report will contain everything needed to plan your internal preparations for the outage and to prepare a comprehensive Request for Quote for the inspections and repairs.

 

A Basis For Your RFQ’s 

Your customized Pre-Outage Plan will include everything you need to prepare a comprehensive Request for Quote for the necessary inspections and repairs.  We will compile a summary of the findings from past inspections and develop a list of recommendations for potential repair work.  We will prepare a comprehensive and detailed suggested Statement of Work for the outage, based on these findings and observations from a unit walk-down.  Incorporating this information into your Request for Quote packages will yield “apples to apples” cost comparisons and few if any surprises on implementation.

 

A Task List For Your Facility

We will review your spare parts inventory and compile a list of recommended parts to have on hand prior to the outage.  We will recommend disposal of any expired or unusable spare parts.

We will also prepare a Critical Path Method schedule based on the defined workscope.  You can use this schedule to plan your expected outage duration and coordinate with any other activities to be conducted during this downtime.

 

What We Provide

The Pre-Outage Planning Package includes:

  • Outage History Review: We review your past outage reports to determine pending or implemented outage recommendations and any changes that may have been made to your unit.
  • Unit Walk-down: We perform a detailed walk-down of the unit, visually inspecting the components and auxiliaries that will help to develop a detailed pre-outage scope of work.
  • Customized Outage Workscope: Formulated from the on-site analysis of your unit, past outage reports, and known issues supplemented by discussion of particulars with you and your staff, we develop a workscope unique to the specifics of your unit and its current condition.
  • Outage Schedule: We take your customized workscope and create a comprehensive Critical Path Method schedule. This exceptional tool outlines a reasonable outage schedule and projected duration, and it can be used as a guide to measure the performance of your outage contractor.
  • Parts List: We compile a “recommended to buy” list determined by a physical review of your unit, prior outage report recommendations, and review of available inventory.

 

In summary, our Pre-Outage Planning deliverables to you will be:

  1. A scope of work tailored to your equipment and outage needs.
  2. A parts inventory and suggested purchase list (to support outage or emergency needs).
  3. A document to assist in the preparation of the scope for RFQ / bid documents.

 

Please CONTACT US today to learn more about how we can help you plan your next turbine outage.

Murray Steam Turbine Inspection & Repairs

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We recently completed another Murray Steam Turbine overhaul at our Steam Path Repair facility in Pevely, Missouri.  We completely disassembled the unit, replaced damaged blades, performed minor diaphragm repairs, performed minor case repairs, balanced the rotor, and reassembled the unit for shipment.  If you have an industrial steam turbine that will need inspection and repair in the future please contact us for a free estimate.  Our qualified repair technicians perform excellent work, and you can rest easy knowing your turbine will run smoothly and efficiently throughout the next run cycle.

Westinghouse Utility Steam Turbine Major Inspection

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We recently completed a Major Inspection on a Westinghouse Steam Turbine and Hydrogen-cooled Generator for a Utility in the Southeast U.S.  The project consisted of inspecting the HP/IP Turbine, LP Turbine, and Valves.  The steam path components were blast cleaned and inspected, with minor blade repairs performed on-site.  The turbine rotors had boresonic inspections performed, confirming the good condition of the components.  Bearings T1 – T4 were inspected and found to be in good condition.  The oil deflectors were re-toothed and machined at our qualified repair facility.  The Governor Valves were sent to our valve facility in Gainesville, Georgia where a flexitallic gasket modification was performed.  We performed on-site machining of the steam chest to accept the newly modified gaskets.  The Throttle, Reheat Stop, and Intercept Valves were all inspected at site.  A laser alignment was performed to align steam path components.  Final reassembly was completed, and the unit was turned over to the customer for startup.   This was another excellent project where we finished on-schedule, on-budget, and most importantly – zero safety incidents.  Great work by the PSG team!

Alstom STF Steam Turbine “A” Inspection

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We recently completed another “A” Inspection on an Alstom STF Steam Turbine.   This inspection consisted of inspecting the valves, bearings, H2 seals, testing of the generator, an LP crawl through, as well as an HP/IP borescope.  Below is a photo of the T1 Bearing Assembly, in which the bearing was dimensionally inspected and clearances verified to be within OEM design criteria.

We 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 Diaphragm Repairs

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We have more steam turbine diaphragms coming through the shop!   It has been a busy turbine outage season and the diaphragms continue to roll through our Steam Path Repair facility in Pevely, Missouri.   Please contact us if you have any diaphragms that may be in need of inspection and/or repair during your next turbine outage.

 

Gas Nitriding of Turbine Components

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One of the durability enhancements we offer for turbine components is gas nitriding.  Gas nitriding is a surface hardening process, where nitrogen is added to the surface of steel parts using dissociated ammonia as the source. Gas nitriding develops a very hard case in a component at relatively low temperature, without the need for quenching. As a result, a very high strength product with extremely good wear resistance can be produced, with little or no dimensional change. For valve components, these material enhancements translate into increased durability and service life and ultimately, reduced maintenance cost.

Gas nitriding can be a time consuming process, which is why we have the equipment in-house to ensure you receive the quickest turnaround times possible during your turbine outage.  If you want to learn more about this and other durability improvements we offer please visit our part manufacturing web page HERE.

 

Balance Chamber Repair vs. Replace

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Save time and money by repairing your balance chamber instead of replacing it.   You no longer need to worry about the hassle of stocking a spare balance chamber, or be surprised by the lead time when you go to order a new one.  We have been repairing balance chambers for utilities across the U.S. for almost 8 years now with great results.   The next time you discuss the future of your balance chamber please contact us to discuss how we can repair your existing component rather than spending the money to purchase a new one.

 

 

Steam Turbine Valve Repair & Upgrade

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Power Services Group provides repairs and upgrades for your valves and valve components. We provide reverse engineering and precision replacement part manufacturing of valve components for virtually all makes and types of steam turbine valves. We also maintain one of the most extensive valve repair equipment inventories and employ the best trained and most experienced personnel in the industry.

We provide efficient and cost effective valve repairs including:

• Bonnet bore refurbishment
• Butt weld modifications
• Seat removal and replacement
• Automated deep bore welding for valve seats
• Stud extraction and hole refurbishment
• ASME Section IX weld repairs
• R-Stamp welding
• Flange face resurfacing (including elliptical)
• Field machining processes for all sealing surfaces and fit areas
• Manual and automatic hard facing of seats and discs
• Reverse engineering and part manufacturing

We can refurbish virtually all makes and models of steam turbine valves to OEM specification:

• Main Steam Stop Valves
• Governor / Control Valves
• Throttle Valves
• Intercept Valves
• Ventilation Valves
• Blowdown Valves
• Equalizer Valves

Our versatile computerized management and maintenance tracking database ensures:

• Detailed inspection reports
• Complete valve maintenance and service history
• Detailed and accurate parts replacement logging
• Itemization of obsolete and current parts
• Tracking of materials and valve parts
• Spare parts inventory
• Digital photos included in all reports

Contact Us today for all of your steam turbine valve component needs!

Excellent Customer Feedback

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We recently received excellent feedback from one of our recent Steam Turbine Major Inspections performed for a Utility customer in the Southern U.S.  This is the type of feedback that makes all of the effort during the planning and execution phases worthwhile.   We are very appreciative of every opportunity we receive, and strive to do our best for each and every customer.  Great to see this type of feedback, and another outstanding job by our field and repair teams!

 

“The response to our RFP was clear, concise, and with a very detailed schedule.”

“It is clear to anyone watching your crew work that PSG has a strong safety culture.”

“The Technical Field Advisor and his team kept us updated and there were no surprises.”

“Of the bids we reviewed for this job, PSG had the most aggressive schedule and then met that schedule. This was a planned 60 day outage that was shortened to 45, so meeting the planned restart date was critical.”

“No leak, no issues, no defects. Very impressive.”

“Very detailed outage report. Better than I am accustomed to seeing.”

“The proposal for the inspection was detailed and thorough. Likewise for all extra work generating during the outage.”

“Documentation was accurate and detailed.”

“I would be glad to have PSG here for our next outage.”

Steam Turbine Diaphragm Repairs

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We have quite a few steam turbine diaphragms being repaired at our Midwest Steam Turbine Repair Facility right now.  If you have a need for diaphragm repairs on your steam turbine please contact us today.