With the team of seasoned professionals that have been established at BRTS®, we have the ability to work with all different sizes, makes and manufactures of steam turbines. When you contact us for your next steam turbine maintenance inspection, we will discuss in detail your needs and expectations. Knowing what you need and expect, we will put our best foot forward to meet your needs and exceed your expectations, with the objective of building a long-term business relationship founded on trust and integrity.
Borescope inspection offers a cost-effective method to view the innermost parts of a turbine, including the entire steam path or the blade entrances, that would otherwise be virtually impossible to see or reach without a resource intensive intrusive disassembly.
Our borescopes have both rigid and flexible length options, a lighting system, a high-quality optical system and an eyepiece to view the projected image. Using flexible, articulating video borescopes to conduct the required inspections eliminates days of labor, rigging and maintenance costs that it would otherwise take to disassemble a component of such size.
We offer basic and advanced inspections of steam turbine valves (stop valve, control valves, dump valves, seal supply valve), bearings and associated components. Steam turbine bearings and seals should be physically inspected during planned outages. This involves opening the bearing housing, removing and inspecting the bearings and seals, and component replacements, as needed.
Other visual inspections of the steam turbine generator train include:
Evidence of steam, oil or water leakage
Evidence of steam deposits
Proper configuration/alignment of all valves
Condition of all control and trip linkages
Condition of electrical components such as instrumentation, conduit, wiring, and insulation
A minor overhaul would typically comprise of some intrusive work but not a total disassembly of the steam turbine.
Typical scope of work includes:
Measurement of turbine axial thrust float and radial lift
Visual condition of shaft journals
Journal bearing clearance and condition
Oil seal clearances
Inspection of governor/control valve, stop valve and trip valve and their seats, and replace the valve stem packing, seats and seals, if necessary
Replacement worn parts and hand lap if necessary
Checking shaft alignment
A major steam turbine generator overhaul involves a detailed inspection and overhaul of the entire steam turbine and generator set including the high and low pressure stages, turbine casing, rotor, seals, and bearings, the generator, and auxiliaries such as the gear, couplings, lubrication and control systems.
Typical scope of work includes:
The full scope of minor overhaul
Removal of the upper half of the turbine casing and recording as found internal clearances
Removal of the rotor to perform a visual inspection of LP and HP stage blade/impellers
Inspection of HP shaft spindle for cracks
Condition assessment of carbon rings or labyrinth seals, and replacement if necessary
Cleaning and inspection of nozzle ring, buckets & diaphragms
Dimensional inspection of rotor journal bearings and seal areas
Checking shaft alignment
Draining of oil reservoir and lube oil coolers; inspection, cleaning and flush of oil coolers
Dismantling and examination of the generator rotor and windings
Preventive maintenance work on control and auxiliary systems
Preliminary Data Analysis
BRTS® provides steam turbine alignment service and precision measurement solutions including:
Shaft and coupling alignment; generator alignment
Turbine geometry, horizontal and vertical joint surface mapping
Turbine nozzle axial clearance, blade tip and bearing clearances, and more.
Our advanced measurement devices and skilled field service team empower us to measure quickly, accurately and precisely and develop targeted data-driven repair strategies while retaining the data for longer term trending, if required. From installation to overhaul and maintenance, our measurement solutions can outperform traditional methods saving valuable outage time and resources.
Inspection & Assessment
With a complete offering of NDT/NDE inspection services, BRTS® is adept at detecting material flaws and defects sooner with a high POD (probability of detection). Our technologies detect even the smallest flaws in turbine componentry that could potentially limit asset operation and risk further damage. This allows our clients to optimize their inspection resources with reliable, repeatable, and accurate inspection techniques, designed to detect some of the most common failure modes for steam turbines, including corrosion, cracking, fatigue, weld defects and leaks.
A few of our NDT/NDE services include:
Eddy Current Inspection
Phased Array Ultrasound
Magnetic Particle Inspection
Liquid/Dye Penetrant Weld Inspection
Turbine Component Repair
Depending on the scope of repair work, BRTS® has the tools to repair components, either on-site or at our network of repair shops located across the country.
Steam turbine components are refurbished through a number of metallurgical processes that restore the component’s metallurgical and dimensional properties. We offer a wide range of component repair and refurbishment services to make your equipment more reliable. We have developed innovative repair strategies that have been meticulously tested and qualified to ensure they provide optimal quality while remaining cost-effective. These methods provide various options, ranging from isolated repair of damaged shaft areas to preventative coatings applied on whole main rotor body.
We have the technological and technical capability to repair shafts with welding methods which involve pre- and post-weld heat treatments to ensure proper metallurgical/mechanical properties. Components are thoroughly inspected using industry-approved NDE/NDT methods. In most cases, these repair methods result in significant reduction in costs and overall repair times.
BRTS® also offers repair and preventative maintenance options based on advanced coating technologies. We use several methods for applying these coatings, including:
Electric arc wire spraying
High-Velocity Oxygen Fuel spraying (HVOF) – liquid fuel and gas fuel
Once the repairs are carried out, we can also take care of your shipping arrangements.
After the main repair, reconditioning and coating, BRTS® can perform a number of additional operations, as required:
Shot peening: To pre-stress (compressive) surfaces that are likely to be fatigue-prone, such as blade joints/roots, which extends fatigue cycle life
Blade balancing: Balanced as a set by moment-weight calculation and sorting; highly recommended to stay as close as possible to the original manufacturing sequence
Guide vane repair: They must be repaired to standardized throat openings
BRTS® provides you with a reliable supply of OEM spare or replacement parts that you may need throughout the entire service life of your turbines within reasonable lead times. Effective spare parts planning is all about having access to the required spare parts at the right time, the right price and in the right condition, and that is what we pride ourselves on providing. Parts are supplied and fitted by our team who understand your business, your QA/QC requirements, and your turbines inside and out, ensuring a seamless journey from obtaining a quote for your part to its installation and testing.
Additionally, we can also review your parts inventory, usage history and downtime and recommend a spare parts strategy for your critical spares.
Tolerance & OEM specifications
Rotor Alignment, Coupling, Bearing Journal, Seals, Diaphragms
BRTS® provides OEM approved tolerance checks on your turbine’s critical dimensions such as journal bearings and shaft alignment, concentricity and runouts.
Start Up & Commissioning
You will have our continued support through the turbine run-up evolution from an outage or commissioning a new project/installation upto steady state. BRTS® can simultaneously record and log multiple turbine run up parameters (such as throttle demand, oil pressure, rpm, exhaust gas temperature, etc.) at short intervals through our dataloggers during your turbine run-ups and analyze data for any potential anomalies.
Recommendations & Improvements
If we detect deviation to specification or performance objectives, we will perform a full assessment to diagnose the root causes and recommend corrective actions ranging from operational improvements to preventive/predictive maintenance initiatives or even modifications, if absolutely needed. The ultimate objective for us and you remain mitigation of risk associated with future unplanned/forced outages as well as performance improvement/efficiency.