Turbine and Generator Repair Services

Fuji Electric has created many new businesses and products since it was founded nearly
100 years ago.
Fuji Electric has evolved to become a global leader in area of “energy and the
environment.” Building upon a platform of core competencies, comprised of five
technological fields—energy, industrial systems, social systems, power electronics, and
electronic devices—Fuji Electric unlocks the potential of electricity with our innovative
businesses and products.
Who is Fuji Electric?
• Fuji Electric is a global manufacturer
with products ranging from the smallest
IGBT module to the some of the world’s
largest power generation systems
• Based in Tokyo, Japan, our company
has a reputation for world-class
engineering and innovation, with a firm
commitment to the environment
• Fuji Electric Corp. of America (FEA) is a
wholly-owned subsidiary of Fuji Electric,
with Corporate HQ in Edison, NJ
• FEA is responsible for the Sales,
Marketing, and Distribution of FE
products in the Americas

– By The Numbers
Established in
1923
24,956
Employees
Worldwide
290,000
Products
Designed &
Engineered
104
Sales & Service
Locations
Worldwide
Products Sold in
Over
52
Countries
$8.6
Billion in
Annual Sales

Fuji Electric has delivered nearly 600 steam turbines and
generators for power plants located throughout the world.
Small-Medium Size Steam Turbines (50MW to 300MW)
Fuji Electric provides single-cylinder and two-cylinder condensing
steam turbines, designed for small and medium scale power
plants with reheat or non-reheat cycles. The small-medium size
steam turbines are best fit to and are compatible with
applications such as coal fired power, combined cycle power,
biomass energy, solar thermal energy, and geothermal energy
Large Size Steam Turbines (up to 1000 MW)
Fuji Electric’s large steam turbines are offered in three-cylinder
and four-cylinder configurations. These condensing steam
turbines are optimized for large-scale power plants, such as coal-
fired and combined cycle power generation facilities
Fuji Electric Steam Turbine Generators

Open, Clean,
Inspect, Close
• OEM-Trained Project Managers
• Comprehensive Toolsets
Repair
• Rotor, Diaphragm, Valves, etc.
• On-Site or in Sullivan Facility
Manufacturing
• Turbine Blade Specialists
• Reverse-Engineer virtually
any turbine component
Generators
• OEM-Trained Generator
Specialists
• Test, Inspect, and Repair most
makes and models
Engineering
• Technical Field Advisor
• Vibration Analysis
• Steam Path Audits
• Consultations
Balance of
Plant
• Fans, Pumps, Compressors, etc.
• Rapid Response within 24 Hours

Corporate Office
RTS Repair Facility
Sullivan, Missouri
U.S. Branch Office
RTS Manufacturing Facility
Houston, Texas
RTS Latin American Office
Medellin, Colombia

30 Years Of Growth And Expansion
RTS is founded as a specialized Turbine Component Repair Company in Sullivan, MO
RTS merges with Critical Path Services - located in Houston, TX
RTS completes construction of new 20,000 Sq. Ft. High Rotor Bay Shop Repair Facility
RTS Turbine Bucket and Component Shop opens in League City, TX
RTS Latin American Division begins operation in Colombia S.A.
RTS begins to offer OCIC Services with the launch of ROC Division.
RTS REM, REAP and ROC begin operations in new 35,000 Sq. Ft. Complex in North Houston, TX
RTS launches full-service Generator Services group
RTS completes 18,000 Sq. Ft. expansion of Specialty Weld Shop and Office in Sullivan, MO
RTS Manufacturing completes ISO 9001:2008 Certification
1984
2005
2007
2010
2011
2012
2013
RTS completes construction of new 10,000 sq. ft. Field Services Facility in Sullivan, MO1999
RTS is acquired by Fuji Electric2015
Reliable Turbine Services has grown steadily and deliberately, always focused on
the delivery of OEM-quality services to its customers

President
Paul “Tim” Weiss
Senior Management
CEO
Mitchell Lardner
Executive Vice President
Don Haag
Sales/
Marketing
ROCC RGEN
ROCC/RGEN
Operations
Manager
Marketing
Sales
Key Account
Management
RGEN
Division Leader
ROCC
Division Leader
RepairsManufacturing
Fuji RTS
Columbia
Operations
Manager
Operations
Manager
Operations
Manager
Vice President
Homero Garcia
Field Repair Division
Field Repair
Operations Manager
CFO
Yoshimi Meya
Accounting
Administration Division
Human
Resources
IT
Chief Technical
Consultant
Ed Campbell Sr.
Latin
America
Houston
Facilities
Sullivan
Facilities

Management and Engineering
Management
Will Surman, ROCC-RGEN Operations
Manager
22 Years of industry experience
OEM Trained, GE
Ronnie Duncan, ROCC Field Service
Manager
OEM Trained, GE, Siemens &
Westinghouse
Greg Duncan, ROCC Supervisor
13 Years in the business and Industry
OEM Trained, GE, Siemens &
Westinghouse
Marshall Duncan, ROCC Supervisor
OEM Trained, Siemens & Westinghouse
Ben Irvine, RGEN Operations Manager
OEM Trained, GE
Mike Valdes, Generator Specialist
Amanda Stamper, Controls Administer
Shawn Browning, Repair Field Service
Manager
Al Wizeman Sr, Repair Facility
Operations Manager
OEM Trained, GE & Westinghouse
Todd Magnuson, Rotor Repair Facility
Foreman
OEM Trained, GE
Matt Cole, REM Operations Manager
Donnie Cullers, REM Production
Manager
David Mata, REM QMS
Ricardo Ibanez, South America
Operations Manager
Engineering
Don McNelly, PE, Corporate
Engineering
OEM Trained, Toshiba
Charlie Wolfe, RGEN Director of
Engineering
OEM Trained – GE, Siemens &
Westinghouse
Brian Biggins, Repair Engineering
Jeff Sowden, REM Engineering

Commitment to Safety
Reliable Turbine Services considers accident prevention of
primary importance in all phases of operation. RTS will
meet or exceed OSHA, Federal, State and Local laws
and Customer rules and regulations
2014 EMR 0.74
2014 TRIR 4.64
2014 Fatality Rate 0
2014 DART Rate 0
Safety Performance Ratings

Safety Meetings
• New Hire Safety Orientation
• Daily Toolbox Meetings
• Weekly Safety Meetings
Planning & Hazard Assessments
• Pre-job safety planning is conducted before starting any job or task
Substance Abuse Policy and Procedures
• Fitness for Duty
• Background Screening
• Drug & Alcohol Screening
Personal Protective Equipment (PPE)
• RTS provides the required personal protective equipment to all employees
Incident Management, Investigation and Reporting

Occupational & Environmental Health
Asbestos
Hexavalent Chromium
Lead
Fall Protection
Confined Space
Housekeeping
Electrical Safety Requirements
Materials Handling Procedures
Lock Out Tag Out
PPE
Power and Hand Tools
Industrial Vehicles
Accident and Incident Reporting
Welding Hot Work
Fire Protection
Hazard Communication

Quality Program Overview
Quality Statement
“RTS and its employees work to meet the requirements of our
customers through commitment to providing consistent quality,
reliability, dependability, and a customer satisfaction that inspires
customer loyalty, and recommendations for future work.”
7 Key Components to the RTS Quality Program
• Requirements
• Planning
• Inspections & Testing
• Data
• Employee Competence
• Continual Improvement
• Customer Satisfaction

• Daily with Job Summary (cost to date)
• Weekly with Job Summary (cost to date)
• Final Job Summary
RTS Project
T&M Cost Spreadsheets
Project Cost Reporting

Turnkey Turbine & Generator Outage Services
Experienced and Skilled Staff
World Class Tooling
Safety, Quality, Schedule and Value
Full Service Provider
Open-Clean-Inspect-Close Division

On-Site Turbine/Generator Turnkey Services
• Project Management Services
• Technical Field Advisor Services
• Steam Path Audit Service
• On-Site Turbine/Generator Repair
Services
• Craft Labor Supervisors
• Craft Working Foremen
• Turbine Millwrights

Major Inspection Toolkits
Up to one half million dollars invested in each Major Inspection Toolkit

Quality Control
Inspected, Organized, and Inventoried Before and After each Project

Quality Control (cont’d)Quality Control

Rapid Response Unit (RRU)
• Centrally based out of Houston, TX
• Mobile and self contained tool unit
• Provides the ability to be on site within 24 hours
• Enough tooling and supplies to start Emergency Outage Repairs
while a Major tool set is in transit to site.
• Capable of supporting (BOP) Balance Of Plant and minor projects
The RTS RRU is a standalone, self-contained tool
unit specifically designed to support any customer
within the lower 48 states with the fastest
response time in the industry. No matter what
the emergency is, the RTS RRU has the
appropriate tooling to start any emergency
outage large or small, major or minor. The RTS
RRU has also executed countless BOP (Balance of
Plant) outages as a standalone unit, saving our
customers the cost of shipping major tool units.

Generator Division
Testing, Inspection, and Repair

• Insulation Resistance
• Polarization Index
• DC Step Voltage
• EL-CID
• AC Impedance
• RSO
TEST
• Locate Coil Insulation
Deterioration
• Detect corona activity
• Boroscope Inspection
of windings and
blockings
• Wedge Mapping
INSPECT
• Re-wedge
• Rotor & Stator Rewind
• Hi-Voltage Bushing
Replacement
• Retaining Rings
• Collector Rings
REPAIR
Generator Services

Generator Advanced Testing
• Transposition Testing
• Vent Tube & Parallel Ring Flow Testing
• Corona Probe Testing
• Partial Discharge Analysis
• Stator Wedge Analysis
• Partial Discharge Testing
• Flux Probe Testing

Generator Rotor Capabilities
• Brushless Exciter test, inspect,
and overhaul
• Field Ground Detector
troubleshooting
• Retaining Ring removal and
inspection
• NDT of Retaining Rings
• Collector Ring Machining
• Collector Assembly
Replacement
• Radial Hydrogen Seal
Replacement
• Rotor Rewinds and High Speed
Balancing

Generator Stator Capabilities
• Connection Ring Modifications
• Bump Testing
• Power Factor & EL CID
• Winding Blocking & Re-tying
• Liquid & Conventional Stator
Rewinds
• Stator Re-wedging
• Flux Probe Installation
• HIT Skid Testing
• High Voltage Bushing
Replacement
• Stator Core Iron Repairs
• Silver-Plating
• Corona & PD Abatement

• Thorough visual inspection is an integral component of any high-quality test and inspection
• Visual inspection may often produce results, which indicate further testing
• Visual inspection is quite inexpensive, while being extremely telling about the condition of
your generator
Off-Line Inspection, Tests & Examinations

Critical Areas for Inspection and Monitoring
Off-Line Inspection, Tests & Examinations

RTS has designed a series of Generator Assessment Testing Evaluation Programs
(GATE) that are designed to be performed during scheduled turbine outages, so that the
critical path is not affected. GATE Testing includes brushless exciter testing and overhauls
Generator Assessment Testing & Evaluation

GATE Generator Testing Programs
GATE 1 GATE 2 GATE 3
Minor Inspection – with
Generator Rotor in place
Major Inspection with
rotor out, limited testing
Major Inspection
extensive testing
• Limited Electrical Testing
• Visual Inspection of unit with
rotor in place
• Reveals pending faults in
winding of the rotor and
armature
• Reveals deterioration of coil
insulation caused by corona
or end winding vibration
• Establishes a “base line” for
evaluating future inspections
and input for establishing
planned major maintenance
activities
• Bore scope Inspection of
windings and blocking, stator
core step laminations and
fingerplates
• Insulation resistance of RTD’s,
armature winding, and rotor
winding
• Armature Winding Test - PI,
Resistance, DC Step Voltage
test, EL CID, Wedge Map
• Rotor Winding Test –
Polarization Index,
Resistance, AC Impedance,
RSO
• Double, “Bump”, and EL CID
included
• Reveals pending faults in
winding of rotor and stator
• Reveals deterioration of coil
insulation
• Reveals possible shorted
laminations
• Reveals loose slot support
system
• Establishes a “base line” for
evaluating future inspections
and input for establishing
planned major maintenance
activities

Turbine Component
Repair Division
RTS Repair Facilities Onsite

Sullivan, Missouri Repair Facility
• Centrally Located in U.S.
• Handles Large Rotors and
Industrial Components
• Large High Capacity Lathes
• Large High Capacity VTLs
• Large High Capacity HBMs
• 100,000 lb. Crane Capability
• Slow Speed Balancing - Up to 100 Tons
• High Capacity Empire Sandblast Booth
• 60”x 60” x 80” Electric Stress Relieve Furnace

• Nozzles / Diaphragms
• Blade Rings
• Curtis & Reversing Rings
• Complete Partition Repair
• T.I.R.’s Flatness, Roundness, Drop,
Horizontal & Dishing Checks
• Expert Installation of Seals, Spill Strips,
& Shaft Packing
• Steam Seal Faces & Horizontal Joints
• Appendages & Set-Back Faces
• Packing Bores & Spill Strip Grooves
• Radial/Axial Seals & Crush Pins
Stationary Equipment Repair
Complete Major & Minor Repairs

Stationary Equipment Repair
Blast clean and NDE / Visual Inspections
• The NDE and Visual inspections provides a complete
listing of missing hardware, damage, and indications to the
component/s
Mechanical inspection
• T.I.R.’s, Flatness, Roundness, Drop, Horizontal & Dishing
Checks. The mechanical check allows the user to identify
potential issues with the stationary components and monitor
that condition over the life of the unit. The mechanical
inspection also assists on the reassembly of the unit.
Complete Partition Repair
• RTS has been providing partition and blade repairs for over
30 years
• 309L, 316L, 304L, Inconel 82, 410
Expert Installation of Seals, Spill Strips, & Shaft
Packing
• Caulked in, Spring backed, & Knurled seals
Steam Seal Faces & Horizontal Joints
• Seal face repairs: patch rings, weld repairs and machining
• Horizontal joint repairs : Picture frame to full joint
Appendages, Set-Back Faces, Packing Bores, &
Spill Strip Grooves
• Repairs to re-establish retaining ledges or build up and
machine to correct an out of round condition
• Repairs to location fits re-establish the L and N prime
locations (or K readings)
• Repairs to re-establish seal groove depth to achieve the
correct depth for installation of seals
Radial/Axial Seals, Centering slots, & Crush
Pins Repairs
• Repairs to the locating fits to return the component location
to design standards
Stationary Blading Process Overview

Rotating Equipment Repair
• Bucket Removal & Installation
• Tenon Welding & Repair
• Shroud Cover Repairs & Replacement
• Tie Wire Repair & Replacement
• Lashing Lug Repair or New Installation
• Installation of Erosion Shields
• Field & Shop Balancing
• Coupling Bolt-hole Line Boring

On-Site Machining ServicesOnsite Machining Services
• Journal Refurbishment
• Stud Removal
• Valve Refurbishment
• Thrust Collar Refurbishment
• Stationary & Rotating Seal
Replacement/Refurbishment
• Portable Machine Shop

Submerged Arc Welding
Automatic TIG Welding
Automatic MIG Bore Welding
Advanced Welding Capabilities
Auto-TIG Stellite Overlay Auto-MIG Bore Welding Auto-TIG Shaft Repair
Sub-Arc Rotor Welding Valve Sleeve Auto-TIG Auto-TIG Bore Welding

Large Component Welding and Boring
Water Runner Erosion Auto-MIG Weld Prep Auto-MIG Bore Weld
Boring Bar Setup Large Bore Machining Bore Restoration Complete

Valve Maintenance & Repair Services

Boring Bars
• 8” Boring Bars x 18’
• 6” Boring Bars x 12’, 8’, and 5’
• 4” x 14’ long, Boring bar
• BB 5000 Climax 2-1/4” Boring Bars
8’, 6’, and 4’ long
• Rotor Coupling Boring Machine
Turning Devices
• Large Portable Turning Devices
(up to 200,000 lb. capacity)
• Small Portable Turning Devices
Field Repair Service Equipment

Portable Slow Speed Balance Machines
• Large Portable Slow Speed Balance Machine (up to 200,000 lb. capacity)
• Small Portable Slow Speed Balance Machine
Vertical Turning Lathe
• Portable 84” capacity (2)
• Portable 150” capacity

Milling Machines:
• Portable Horizontal Mill, 6’ x 4’ table
• Horizontal Joint Milling Machines
• Climax Portable Key Cutters
• Climax Flange Facers
Stud Removal Machines:
• Stud Buster - 15 HP hydraulic
• Knee Mill hydraulic
• Knee Mill hydraulic with single point
threading capability
• #5 Lamina Drill

Airfoil and Component
Manufacturing Division

Turbine Blades and Buckets
• RTS manufactures most OEM
replacement blades, including
GE, Alstom, Toshiba,
Westinghouse, and others
• RTS’ full service manufacturing
facility includes an advanced fleet
of 4, 5 and 8 axis Milling
Machines. Our CNC lathes and
EDM’s are set up to handle all
HP/IP and most LP blading needs
Using advanced reverse- engineering
software and hardware, RTS is a
leader in both Quality and Delivery of
airfoils and blading in the power
generation industry.

Large Variety of Components
RTS’ Manufacturing Division supports our
customers with the rapid delivery of turbine
blading and a large variety of other turbine
components.
RTS stocks a wide array of material including:
B-7, B-16, 403, 422, 17-4 PH, and Hastalloy.
This allows RTS to respond to our customers’
needs immediately

• Utilizing State of the Art Scanning and
CMM technology, RTS is capable of
turning a customers sample into a
detailed manufacturing drawing with
speed and precision. This allows us to
provide a vast array of Turbine and
Generator Components ahead of the
competition.
• We utilize the Industry Standard Design
and Programming platforms of
Solidworks and Mastercam, which
enable us to provide high quality results
and allow us to work seamlessly with
Your Engineers when required or
desired
• RTS’s skilled engineers, drafters and
programmers allow us to meet and
many times exceed OEM specifications
Engineering

REM Quality
Quality Policy Statement
“Reliable Turbine Services is committed to our customer’s
satisfaction through continual improvement of our manufacturing
processes and services to ensure they meet or exceed the requirement's
and specifications of our customers and industry standards.”
- Paul ”Tim” Weiss, President
ISO 9001:2008
• As of November 2013 RTS
has received ISO 9001:2008
quality system certification.
• RTS’s full quality manual and
ISO certificate is available
upon request to all
customers.

What Makes A Great Service Provider?
Experience
• RTS has a combined 300 Years Management
Industry Experience
Turnkey Service Capabilities
• Experience Field Service Teams
• Able to perform virtually any Turbine Repair
• Critical Component Manufacturing such as
Turbine Blades
• Generator Test, Inspect, and Repair
• Balance of Plant Equipment
Engineering Capabilities
• Reverse Engineering of components
• Project Technical Advisors
• Steam Path Audits
• OEM-Trained Engineers available for critical
problem solving
Customer Service
• Dedicated year-round customer service
specialists
• Dedicated on-site single point of contact for
your outage team
• Dedicated RTS Project Control Specialists to
manage your project from the RTS Corporate
Offices
Guarantees
• Turnkey Project Warranties – we take
responsibility for your outage
• We take accountability for the project success
and will continue to work with you until
everyone is satisfied with the outage results
• RTS has a 98% customer retention rate due to
the fact that we listen to our customers, and
follow through to ensure every outage is a
success

Experience Customer Service Turnkey Service Capability Project Accountability Engineering Reliable
Turbine Services Powered By Fuji Electric Quality Turbine And Generator Services Turnkey Service Capability
Engineering Customer Service Experience Powered By Fuji Electric Project Accountability Reliable Turbine
Services Quality Turbine and Generator Services Turnkey Service Capability Powered By Fuji Electric Project
Accountability Reliable Turbine Services Customer Service Engineering Experience Quality
Turbine And Generator Services Customer Service Turnkey Service Capability
Project Accountability Engineering Reliable Turbine Services Powered By Fuji Electric Quality Turbine And Generator
Services Turnkey Service Capability Experience Engineering Customer Service Experience Powered By
Fuji Electric Project Accountability Reliable Turbine Services Quality Turbine and Generator Services
Turnkey Service Capability Powered By Fuji Electric Project Accountability Reliable Turbine Services Customer
Service Engineering Experience Quality Turbine And Generator Services Experience Customer Service
Turnkey Service Capability Project Accountability Engineering Reliable Turbine Services
Powered By Fuji Electric Quality Turbine And Generator Services Turnkey Service Capability Engineering Customer
Service Experience Powered By Fuji Electric Project Accountability Reliable Turbine Services Quality Turbine and
Generator Services Turnkey Service Capability Powered By Fuji Electric Project Accountability Reliable
Turbine Services Customer Service
Everything you need in a
Quality Service Provider

Experience Customer Service
Project
Accountability Engineering
Turnkey Service Capability
Everything you need in a
Quality Service Provider

Turbine and Generator Repair Services

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Viewers also liked

Viewers also liked (7)

Similar to Turbine and Generator Repair Services

Similar to Turbine and Generator Repair Services (20)

Recently uploaded

Recently uploaded (20)

Turbine and Generator Repair Services