Allis-Chalmers Industrial Steam Turbine Major Inspection

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Power Services Group (PSG) was contracted by an industrial customer in the Midwest U.S. to perform a major inspection of their Allis-Chalmers steam turbine generator.
This unit is a non-condensing steam turbine that is directly coupled to an Allis-Chalmers air cooled generator. The turbine and generator set are of a three-bearing
design.

During the project, a Safety Meeting was held prior to the start of any work. The Safety Meeting topics were based on work activities to be performed during the shift. In addition, hazardous observations which could impact the safety of the team were discussed and resolved. Prior to performing work, a Job Safety Analysis (JSA) form was completed by the work team. This project had no accidents and no first aid incidents.

The steam path components, once removed, were dust blasted and received nondestructive examination (NDE). The NDE revealed minor indications on the stationary blading, and no repairs were deemed necessary at this time. The turbine rotor and stationary stage 6 were shipped to our steam path component inspection and repair facility in Pevely, Missouri for replacement of the 7, 8, 9 and 10 rotating blades, and repairs to the #6 stationary stage.

The generator field was removed from the stator and both the generator field and generator stator, received visual inspections and electrical testing. The generator field was shipped out to receive a retaining rings-off inspection. The stator was ice blast cleaned, received a re-wedge of the stator core windings, and final coated with an insulating epoxy.  The journal bearings were removed and visually and dimensionally inspected and received dye-penetrant and ultrasonic testing. Inspections revealed that all of the bearings, new and in service, were in excellent condition. The pedestal oil deflectors were removed and visually and dimensionally inspected. All were found to be beyond industry standard clearance tolerances and were replaced.

The inlet control and extraction control valve racks were removed, cleaned and visually and dimensionally inspected. The valve poppets and seats were NDE inspected and found to be in very good condition and were returned to service. Some of the valve linkage bushings and pins were found to be worn and were replaced. The trip throttle valve (TTV) and operator were removed, disassembled, cleaned, and inspected. All inspections were approved and the components were returned to service. The lube oil cooler was removed and replaced by plant personnel. The lube oil system shaft driven main and steam driven auxiliary oil pumps were removed and received inspections. The main oil pump (MOP) and the steam driven auxiliary oil pump, (AOP) were found to be in good condition and were reassembled and returned to service. The lube oil reservoir was opened by PSG and initially cleaned by plant personnel. Some sediment and sludge were found during the initial cleaning of the lube oil main reservoir. PSG performed a final vacuum and hand cleaning of the interior of the reservoir prior to the lube oil system high velocity oil flush (HVOF). A lube oil system HVOF was performed utilizing an external pump and heating/filtering skid. The flush was ran for approximately 72 hours and was completed once system cleanliness was acceptable.

The system trip devices were inspected, cleaned and flushed; all linkages were checked for wear and proper freedom of movement. The mechanical over speed trip test was completed after initial startup and the unit was later tied on-line. PSG personnel demobilized the job site and were released to travel after another successful project startup.

Zero safety incidents, quality work, Nice job team!

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.

 

3D Component Scanning

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It’s that time of year again!  When turbines are running throughout the summer season it’s a good time to scan any common parts that you may need to order again in the future.  With our portable metrology-grade 3D scanning equipment, we are able to scan components within extreme accuracy.  You can ship your components to our shop, or we can bring the experienced technicians and scanning equipment to your facility and analyze the components right there at your site.  If you have any component engineering needs please give us a call.  We’d love the opportunity to help in any way we can.   CLICK HERE for our phone and email contact information.

The Right People

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A company built on industry leadership, knowledge and experience!

We employ industry-experienced professionals who work together consistently as a cohesive team, anticipating problems and formulating best solutions. Our team approach allows us to better organize and manage your project details and plan for contingencies. This organizational structure creates a project team that runs smoothly… So your project runs smoothly too.

Project Management
Good project management is key to a successful outage. Our Technical Field Advisors and Foremen are industry veterans, with experience across all the units we service. Many of them started their careers with an OEM. They offer the technical and project management proficiency to guide your specific project and are qualified to provide clear options and recommendations when repairs are required.

Project Coordinator
The on-site Project Coordinator manages supplies, parts, services and contractors and reports costs on a daily basis. This allows us to manage your project with a single Technical Field Advisor, reducing costs and providing seamless control.

Turbine Mechanics
Each Foreman builds a base crew of Mechanics who work together consistently. We also provide formal training and advancement for a pool of mechanics who are utilized when larger crews are needed. Together, they have the necessary skills and experience, and know our tools, procedures and safety.

Remote Turbine Consultations

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Power Services Group offers remote consultative services for those customers looking to resolve issues on their turbine power island.  Many facilities have postponed or delayed outages this year, and that may extend turbine run times to longer than some may be comfortable with.  Many turbines may have had outages planned to address issues currently being experienced.  Those outages are now postponed, and facilities must make alternative plans to address any operational issues.  At PSG, we can provide remote assistance to help you develop solutions to any potential problems you may be facing.  We will offer our opinion based on the information gathered remotely between your plant personnel and our qualified Technical Advisors.  This may include any operational data or photographs related to the issue being experienced, telephone conversations between involved parties, and remote video meetings by telephone to allow our Technical Advisors personally experience any sights and sounds that may be the result of the issue you are experiencing.  At PSG, we are here to help.  We understand that it may not be the most optimal time to have outside personnel visiting your facility, so we will do everything possible to help you develop alternatives through our remote consultative services with our qualified Technical Advisors.

We have expertise on most Steam Turbine OEM types (List of Steam Turbine OEMs we perform services on), as well as various types of Combustion Turbines (List of Combustion Turbine OEMs we perform services on).

You can call us at any time to begin discussions at 800-226-7557, or email us through the following link:  Contact Us.

If you ever experience an emergency situation, we have Technical Advisors just a phone call away at 888-MrTurbine.  We are available 24/7, 365 Days a year.

We look forward to helping you ensure your turbine is operating as efficiently as possible until your next turbine inspection.

 

Turnkey Outage Management Services

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At Power Services Group we believe in taking responsibility for the successful outcome of your turbine overhaul project.  That is why we provide highly qualified and experienced Project Managers and Technical Field Advisors to oversee the successful execution of your turbine outage.  Our Technical Field Advisors are trained and experienced on a variety of OEM types:

 

ABB & ABB VAX          Allis Chalmers          Alstom          Ansaldo          BBC          DeLaval          Dresser-Rand

 

Elliott          Fairbanks Morse       Franco Tosi          GEC          General Electric          Metropolitan Vickers

 

Mitsubishi          Murray          Parsons           Peter Brotherhood          Shin Nippon          Siemens          Stal Laval

 

Terry          Thermodyne          Toshiba          Turbodyne          Westinghouse

 

Power Services Group (PSG) has the ability to provide full turnkey inspections on turbine generators for most OEM manufacturers. PSG provides total turnkey outage performance including technical direction, engineering, project management & coordination, supervision, labor, tooling, repairs, parts sourcing and/or manufacturing, and start-up support. We support fossil and nuclear steam and gas turbines ranging from 1MW to 1,300MW for all major OEMs.  We service all industry types including, but not limited to: industrial, paper/pulp, marine, steel/aluminum, chemical and petrochemical, utility, nuclear, and independent power producers.

Please contact us today to learn more about how we can help you achieve your goals for your next turbine maintenance inspection.

Another Steam Turbine Rotor Leaving the Shop!

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We have another Steam Turbine Rotor leaving the shop!  This is for an industrial steam turbine in the Northern U.S.  We blast cleaned the rotor,  removed some of the existing blades and replaced with new, installed new covers, and balanced the rotor upon completion.  In addition to the rotor work we performed major repairs to specific diaphragms as well.  Another great job by our team at the steam path repair center in Pevely, Missouri!

Steam Turbine Front Standard

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A critical component of a steam turbine is the front standard.  Ensuring all of the components are suitable for continued operation should be a staple of any thorough inspection.  The photo below is the front standard on an approximate 100MW GE Steam Turbine.  Engineering at its finest!

 

Turbine Services Tool Containers

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We’ve recently re-painted some of our tool containers – and they are looking good.  Nice work by our team at our Knoxville, Tennessee Logistics Center.

PSG maintains fully configured containerized tool sets, ready to be shipped to your location at a moment’s notice. The entire tool set fits on a single truck bed for ease in transport. Our logistics team is ready to ship these tools to meet your need – using best available rates for pre-planned outages, or expedited using 24- hour driving teams for emergencies.

Once we arrive at your site, we can quickly mobilize to efficiently begin work on your outage. If space and crane capacity is available, we can lift a container to your turbine deck and roll­ out our tool cabinets. If space is tight, we can lift the individual cabinets into place or transport them by forklift.

Our Project-Specific Planning allows us to customize the tool set for the job. We have what we need on-site, even planning for contingencies. The more organized we are, the more efficient our project teams can be, and that means less downtime for you.  Our fully-equipped trailers focus on safety and reduce labor costs so we can get your unit back online efficiently.

Specialized for Specific Needs

Besides Major Inspection tool sets we have developed many other customized sets including:

SAE/Metric

Steam/Combustion

Major/Minor/Valve & Bearing

Emergency Response

Organized for Efficiency

Our tools are organized for efficiency. Small tools are organized in movable heavy duty cabinets, with each drawer labeled in large letters. Tools are organized in foam cutouts within the drawer to make it easier to locate and replace a tool – a specific place for a specific tool. Large tools are organized in Gang Boxes, with hooks or pegs labeled for every tool.

We have a standardized arrangement for all our tool sets, so if a mechanic is familiar with one, he is familiar with all. Our mechanics take pride in our tool sets and retrieve and replace their own tools, as required, so there is no need for a tool attendant. This increases productivity and makes sure the right tool is used for every task.

Office Facilities

We bring a dedicated office trailer to facilitate project planning and communications. The trailer contains lights, power outlets and printers for management support, and is fully supplied with materials for lockout, badging, reporting and other support services.

After the tool boxes are removed from our separate tool container, it is used as a break room for our mechanics.

On-Site Repairs

If turnaround time is a critical factor in your outage, then we can perform most all machining and rotor repair using specialized portable equipment delivered to your remote facility. We will work with you during pre-outage planning to determine if this option is right for you.

On-site tooling is available for Rotor/ Seal Turning

Low Speed Balance

Broken Bolt/Stud Removal

Generator Rotor Rewind Collector Ring Grinding

Valve & Bearing Inspection

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Turbine Generator Maintenance (TGM) was contracted by an industrial customer in the United States to perform a valve and bearing inspection on their General Electric (GE) condensing steam turbine and hydrogen-cooled generator. The turbine and generator set is of a four bearing design.

During the project, a Safety Meeting was held prior to the start of any work. The Safety Meeting topics were based on work activities to be performed during the shift. In addition, hazardous observations which could impact the safety of the team were discussed and resolved. Prior to performing work, a Job Safety Analysis (JSA) form was completed by the work team. This project had no accidents and no first aide incidents.

The generator rotor remained in the stator and both of these components, the generator rotor and generator stator, received visual inspections and electrical testing.  The journal bearings were removed and visually and dimensionally inspected. The pedestal oil deflectors were removed and visually and dimensionally inspected. The #3 outboard (OB) and #3 and #4 inboard (IB) oil deflectors showed to have excessive clearance. These deflectors were conveyed to a local machine shop for repairs. The remainder of the deflectors were cleaned and returned to service.

The inlet control valves (CV) were removed, cleaned and inspected. The valve seats and poppets were found in acceptable condition, CV’s 3, 4, 5 and 6 received new stems sourced from customer spares. The valve bushings showed to be worn and were recommended for be replacement at the next planned outage. The main stop valve (MSV) and operator were disassembled, cleaned and inspected. All components were approved for reassembly and were returned to service.

The lube oil system main, AC and steam driven oil pumps were disassembled and received inspections. The main oil pump (MOP), which is driven by the turbine rotor, was returned to service with no repairs being necessary. The steam driven auxiliary oil pump (AOP), was found to have acceptable clearances and was reassembled and returned to service.  One row of carbon steam packing was found to be damaged and was replaced. The AC driven oil pump was found to have acceptable clearances and was reassembled and returned to service. The lube oil reservoir was opened and cleaned.

The generator coolers and air ejector condensers were opened on the water side for inspections. The tubes were rodded out, flushed and vacuum tested. All were OK and the components were reassembled. The lube oil coolers were opened and cleaned.  The system trip devices were cleaned and received visual inspections; all linkages were checked for wear and proper freedom of movement. The devices were latched and checked for tripping operation. The governor speed control trip latch oil pressure trip cylinder piston rings were found to be seized. New rings were manufactured and installed.

Upon startup, the unit operation was accepted and the unit placed online.  Our personnel demobilized the job site and were released to travel the following morning.

Another successful project and satisfied customer.