We are thrilled to announce the expansion of our services with the opening of a new steam turbine repair center of excellence in Gainesville, Georgia!

This state-of-the-art facility will open in the fall of 2024 and offers comprehensive steam path and valve repair services.

This expansion underscores our steadfast commitment to providing exceptional service and support to our valued customers. Our new facility features the latest repair technology and a highly skilled team of engineering and repair professionals, all dedicated to meeting your needs.

Prepare for an enhanced experience! We look forward to serving you from our expanded Gainesville, Georgia location.

Join us on this exciting journey and stay tuned for more updates!

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We’re delighted to share that we’re expanding our capacity to serve you better! Introducing our brand-new steam turbine repair center of excellence in Gainesville, Georgia.

The facility, scheduled to open in fall 2024, will provide full steam path & valve repair services.

This expansion of our Gainesville, Georgia campus reflects our unwavering commitment to exceptional service and support for our valued customers. Our cutting-edge facility boasts the latest repair technology and a skilled team of engineering & repair professionals—all dedicated to meeting your needs.

Get ready for an elevated experience! We eagerly anticipate serving you from our expanded Gainesville, Georgia location.

We look forward to you being part of our journey! Make sure to stay tuned for more updates!

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We’re delighted to share that we’re expanding our capacity to serve you better! Introducing our brand-new steam turbine repair center of excellence in Gainesville, Georgia.

The facility, scheduled to open in fall 2024, will provide full steam path & valve repair services.

This expansion of our Gainesville, Georgia campus reflects our unwavering commitment to exceptional service and support for our valued customers. Our cutting-edge facility boasts the latest repair technology and a skilled team of engineering & repair professionals—all dedicated to meeting your needs.

Get ready for an elevated experience! We eagerly anticipate serving you from our expanded Gainesville, Georgia location.

We look forward to you being part of our journey! Make sure to stay tuned for more updates!

Focus Areas

• Fabrication
• Valve Overhaul & Repair
•  Stationary/Steam Path Inspection and Repair
•  Turbine Rotor Inspection and Repair
• Single and Small Multi Stage Turbine Overhaul
• Miscellaneous machining

Capabilities

• 65,000 total square feet
• 2-Ton Crane capacity with 15,000 square feet under hook
• 25-ton Crane capacity with 15,000 square feet under hook
• Provision for future addition of 50-ton Crane capacity with 15,000 square feet under hook
• Dedicated Diaphragm Repair Cell

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Rotor Cleaning & Inspection: Ensuring your rotors are in top condition.
Diaphragm/Blade Ring Cleaning & Inspection: Precision care for crucial components.
Rotor Re-blading: Upgrading your system with the sharpest solutions.
Stationary Partition Repairs: Keeping the static parts of your turbines reliable.
Rotor Weld Restoration: Reinforcing the heart of your machinery.
Miscellaneous Machining: Custom solutions for unique challenges.
Trust us to keep your turbines turning efficiently!
#PevelyFacility#PowerGeneration #TurbineServices

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 Exciting News from Gainesville, Georgia!

Our Southeast Turbine Repair & Part Manufacturing hub is the heart of innovation and precision. Specializing in:

• Parts Manufacturing
• Fabrication
• Valve Overhaul & Repair
• Hard-faced Overlay (Stellite, Ultimet, etc.)
• Miscellaneous Machining

And that’s not all… We’re expanding! A brand new 65,000 sq ft facility is on the horizon, ready to enhance our capabilities and serve you better.

Stay tuned for more updates and remember, for unparalleled quality and expertise, #ChooseGainesville!

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Danger Point – Accidental Hose Breach

If a compressed air hose is breached, the escaping pressure snaps the hose like a whip, attacking both personnel and equipment. The released air may contain scale from the fixed lines, or stir up loose material which can be driven into the eye like shrapnel. Protect the hose from cuts and blow-outs by protecting it from sharp and burred objects. Make sure there is plenty of slack at the connector — stress at the connector can weaken the hose and cause a blowout. Protect the hose from foot and vehicle traffic. Prevent kinks by coiling the hose when not in use and never hang it over a nail or hook. Use a broad support, preferably a curved surface.

Danger Point – Connectors

A hose is breached each time you disengage the connector. Proper procedure is to bleed out the pressure before disengaging a hose. Shop air outlets should not be “live” but should include a valve before the connector, and a bleed valve between that valve and the connector. If a bleed valve is not available, release hose pressure through an air ratchet or similar tool. Check to see that connectors are fastened securely. As an added safeguard, attach a positive locking device such as a safety clip or retainer at the source and at the attachment. This is especially important when using vibrating attachments such as chisels on a chipping hammer.

Danger Point – Blow Gun Nozzle

The blow gun attachment is a particularly dangerous tool. The air stream can blow an eye from its socket, and/or rupture an eardrum. Air driven beneath the skin can cause internal hemmorage and intense pain. Air that enters a body opening can burst internal organs and cause slow, agonizing death. Air used to clean surfaces can drive particles into the eye. Never use compressed air to clean off your clothes. Keep air pressure below 30 psi when cleaning surfaces or deep holes. Wear cup-type goggles and set up shields to protect passers-by, and others in the area. Never use air to remove dust – it just ends up in your lungs.

Danger Point – Unsafe Hoses

All hoses eventually wear out. Your hose may be ready to fail if you discover:

When any of these conditions occur, it is good safety sense to immediately remove the hose from service. Once removed, the hose can be carefully inspected and replaced if necessary.

Ask your own safety question by contacting Mr Turbine.

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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.

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Contamination and Erosion

All gas turbines experience losses in performance with time and the compressor has a significant impact. In a typical heavy duty axial compressor a 1.0% loss in compressor efficiency will create a 1.1% loss in output.

Compressor fouling is a serious concern and can be mitigated or recovered through proper operational practices. Dirt, oil and debris in the front stages of the compressor can result in a loss of mass airflow, and contamination in the last stages can result in power-robbing drops in the pressure ratio. These foreign objects can also erode or damage surface finishes and airfoil geometry, resulting in reductions in airflow and pressure ratios. Water-washing can partially clean contaminated blades, but recapturing full efficiency can only be achieved by opening the unit and mechanically cleaning the surfaces and replacing damaged components.

While the unit is open, the compressor can be coated to make the airfoils less susceptible to dirt and debris and increase the ability of the water wash to thoroughly clean the airfoils. Adding filtration to the inlet also helps maintain a clean compressor.

Leakage

In a typical heavy duty gas turbine compressor section, air is compressed to many atmospheres pressure by the means of a multiple-stage axial flow compressor. The compressor design requires highly sophisticated aerodynamics so that the work required to compress the air is held to an absolute minimum in order to maximize work generated in the turbine. Any changes to this precise geometry can materially affect performance.

Air leakage through and around components significantly rob performance. One example is a bleed valve which remains open during operation. Another would be a leak at the 4 way joint. While sealing the horizontal and vertical joints are necessary as the machine ages and the casing warps, sometimes all that can be done without purchasing new casings is to manage the leakage. Leaks are more costly to the aerodynamic cycle at stages further down the axial compressor. A leak at an early stage might not be worth the cost of repair.

At the tail end of the compressor rotor is the inner barrel, which provides the inner diameter flow path and the internal support for the exit guide vane (EGV’s). On the internal surface of the inner barrel there is a labyrinth seal called the high-pressure packing seal. On field inspections we often find significant rubbing of the rotor to the labyrinth seals of up to 90 mils. This excess clearance and thus increased airflow results in a loss in performance.

This leakage can be minimized by retrofitting the high-pressure packing seal area with a wire brush seal. The wire brush seal is flexible and will deflect (not wear) if it does contact the rotor. The bristles of the brush deflect in the direction of rotation so that a closer effective clearance can be maintained. The seal even remains intact during transient events where some vibration occurs. Also, there will be less performance degradation over time since the wire brush will bounce back to the original configuration after contact. These losses can only be repaired during an overhaul.

Calibration

Air temperature and pressure can seriously affect performance. Since the gas turbine is an air-breathing engine, its performance is changed by anything that affects the density and/or mass flow of the air intake to the compressor. When measuring performance degradation over time, remember to correct for changes to the reference conditions of 59 F/15 C and 14.7 psia/1.013 bar. Differing ambient air temperatures affect the heat rate. Correction for barometric pressure is more straightforward. A reduction in air density reduces the resulting airflow and output proportionately, but the heat rate and other cycle parameters are not affected.

Humidity is an often overlooked factor affecting performance. Humid air, which is less dense than dry air, also affects output and heat rate. In the past, this effect was thought to be too small to be considered. However, with the increasing size of gas turbines and the utilization of humidity to bias water and steam injection for NOx control, this effect has greater significance.

TGM can help you assess your unit’s existing performance versus its original design and establish a performance measurement process to accurately capture decreases which could indicate the onset of serious problems.

Turbine Generator Maintenance can help you achieve your goals in restoring your machine to its new and clean condition or upgrading its performance to achieve higher output, lower emissions or both.

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Basically, the generator load is a gigantic magnetic braking force.  In normal turbine operation, the driving force (steam or gas pressure) is equal to the braking force of the generator and the turbine-generator speed is constant. When the braking force is suddenly removed, the turbine force must also be removed before the turbine and the generator components rapidly spin out of control, potentially causing millions of dollars in damage. Your overspeed protection system must be ready to avert this disaster.

Overspeed protection devices can be mechanical (trip weight), electrical or a combination of both.  Units can have a mechanical governor or EHC controls.  Regardless of the mechanism, all overspeed protective devices are designed to stop the steam or fuel from entering the turbine(s) upon an increase in normal speed.  Most overspeed trip mechanisms are set to trip the unit at 110% of rated speed, but most turbine-generators are designed to temporarily operate at up to 120% of rated speed. Lower overspeed settings may be required for certain reheat units and nuclear applications.

Your turbine should have at least two trip devices – electronic and mechanical. Both systems must be inspected and tested regularly – please check your operating manual or call us with any questions.

Failure to remove the driving force (steam or combustion) can unleash torque forces which can destroy your turbine-generator. For example, a modest-sized steam turbine can have a start-up flow of 40,000 lb/hour to synchronize the generator to the grid and close the breaker. As the generator takes on load, steam flow is increased from the initial 40,000 lb/hour to a much greater flow (let’s say 2,000,000 lb/hour) and the turbine goes no faster! That additional 1,960,000 lb/hour steam flow has created torque to drive the generator.

Under a full load rejection, the generator armature reaction that opposes those additional pounds per hour of steam flow is suddenly removed. Now there is an unopposed 1,960,000 lb/hour of steam flow accelerating the turbine. We should not be concerned so much with how fast the turbine will go, because the speed will be way too much. We are more concerned with how fast the turbine-generator will accelerate and how quickly the turbine inlet steam valves will have to close. If the steam is not shut off, the turbine achieves the 120% rating value in seconds. Seconds later, bearings are failing, blades are failing, disks are failing or being pushed into the diaphragms, generator retaining rings are failing, and the rotor is being pushed into the core.

Combustion turbine operators may feel safer because the compressor load acts as an additional brake on acceleration. However, this retarding force will only afford you a few extra seconds. Whether steam or combustion driven, your turbine-generator needs to be ready and personnel need to be ready. There is no warning and you have so little time to act!

Minimize overspeed risk by:

* Having at least two trip devices – electronic and mechanical.

* Properly calibrating your overspeed devices.

* Routine testing to exercise those devices that must operate in an emergency.

* Reporting unusual events that could be indicators of increased risk (a sticking valve that fails to respond to load demand is a good example).

* Not performing tests (exercises) in severe weather conditions where the risk of load rejection is much higher.

Follow the OEM’s recommendation’s for the recommended testing frequency of your over-speed trip and record it’s trip speed.  A good time to test is when you are required to shut down the unit and load is removed from the generator.

The bottom line is that your turbine-generator needs to be ready; personnel need to be ready, as there is no warning and you have so little time to act!

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We recently helped a plant with three GE Frame 6B gas turbines that had lost power over successive overhauls. Units 1 and 2 had been overhauled by the OEM in the last few years and Unit 3 had been overhauled in 2006 by a competitor. All three units had been experiencing an unexplained loss of power.

A gas turbine needs to breathe air – and a lot of it – to make horsepower. The inlet guide vanes (IGVs) on a heavy duty gas turbine are designed to modulate (open and close) in response to commands from the control system to regulate this air flow. These commands control turbine exhaust temperature, protect against a compressor “stall” or “surge” (extremely damaging to the compressor blading), and other controlling functions. The IGVs look like little airplane wings that rotate or pivot to allow more or less air into the compressor. They are calibrated to the turbine control system by measuring the actual vane angles with a machinist’s protractor and inputting the readings into the control system. This lets the electronic controls know physically where they are so that the system can properly control the unit.

On checking Unit 1 and 2, the IGV calibration was significantly out of calibration. Unit 3 wasn’t as bad but it was also slightly out of calibration., We accurately calibrated the IGV’s to the OEM control specifications on all three units.

The results of this work were impressive. The heat rate (fuel efficiency) improved on Unit 1 by about 2%, gained 2.5 mw on Unit 2 and 0.5 mw on Unit 3. This made a significant contribution to the customer’s bottom line at the expense of just a few days of work.

The IGV calibrations are just one of the critical instruments or calibrations that could affect power production. Contact PSG^® for a full analysis of any reductions to the heat rate or power output of your turbine

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