Summer Maintenance Checklist

Summertime is almost here!  That means summer run season is beginning and many turbine generator sets will be in operation over these next few months.  While the units are in operation that provides facilities with the opportunity check some items off of the to-do list.  We offer a variety of non-turbine outage services during the summer months.  Please see our common summer services below and let us know if there is anything we can help you accomplish.

Contact us HERE to request a quotation.

COMMON SERVICES OFFERED:

  • Running Condition Assessments to assess your Steam Turbine
  • Pre-planning Support for Upcoming Outages
  • Inventory Recommendations for Spare Parts
  • Evaluation of Repair Programs
  • Evaluation of Preventative Maintenance Programs
  • Emergent and Unplanned Maintenance
  • Evaluate Plant Performance Issues
  • Owner’s Representatives for Plant Projects
  • Temporary Maintenance Labor
  • Parts Reverse Engineering and Manufacturing
  • Field Machining of Components

Frame 7B Combustion Inspection

PSG mobilized a Technical Field Advisor, Foreman, Turbine Mechanics, and Tooling to a Utility site in the southern U.S. to perform a combustion inspection ‘’CI’’ on a GE MS-7000B combustion turbine.

The job consisted of removing and replacing all combustion parts and associated consumables. The fuel nozzles, combustion liners and transition pieces were removed and replaced with OEM refurbished components.

The bullhorns, combustion chambers, crossfire tubes, retainer clips and lid covers were returned to service with no replacement necessary. Transition piece hardware was replaced with new parts and the crossfire tubes and retainer clips were returned to service with minor wear being noted. All associated flange gaskets were replaced with new OEM consumable parts in all 10 combustion cans as a preventive maintenance practice. New flange bolting hardware was also installed as a preventive maintenance practice.

The combustion wrapper was removed to better access the transition pieces and have a better visual inspection of the 1st stage nozzle, all wrapper case bolting was replaced with new upgraded components.

The inlet was visually inspected and found to be in overall good visual condition.

A visual inspection of the exhaust plenum showed the assembly to be in overall good visual condition with minor wear noted.

The end result was another successful combustion inspection on a Frame 7B combustion turbine, and most importantly, a satisfied customer.

The Right People

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

 

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.

 

Wind Turbine Shaft Machining

 

We recently received a call to perform an uptower repair of a damaged shaft inside a Wind Turbine.  We have experienced technicians that are specifically trained for uptower Wind Turbine repairs, and have the expertise and equipment to successfully execute these projects.  The final results are a safe, quality project – with a shaft that is back within OEM specified tolerances.  The photos below show the before and after of a shaft in need of refurbishment, and the excellent work that our technicians perform.  The end result is another satisfied customer…

 

Before

After

Who is Power Services Group?

Power Services Group is a market leader in providing integrated, turnkey solutions for the maintenance, repair and overhaul of turbines and generators for the power generation, oil & gas, and process industries.

We have multiple locations within the United States, each ready to provide the best possible service to our customers.  These locations are fully staffed to meet the demands of our customer base, and it is the quality of our personnel throughout the organization that make us the great company we are today.  We look forward to continuing to earn your business through hard work, and a dedication to safety and quality on every job we perform.

Another Steam Turbine Rotor Leaving the Shop!

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!

Turbine Services Tool Containers

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

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.

Nuclear Steam Turbine Services

Power Services Group (PSG) provides turnkey services for nuclear steam turbines and generators for most OEM manufacturers. PSG provides total turnkey outage performance including technical direction, project management & coordination, supervision, labor, tooling, repairs, parts sourcing and/or manufacturing, and start-up support.  We also specialize in nuclear turbine valves at our Gainesville, Georgia facility.  We can provide complete valve overhaul services to prepare your nuclear steam turbine valves for their next run cycle.  We support fossil and nuclear steam turbines up to 1,300MW for all major OEMs.

If you are looking for a cost-effective, quality alternative for your nuclear steam turbine services please give us a call or send us an email and we’ll provide you with a free quotation for your next inspection.