Blade and vane repairs: 

•   Inspection for erosion, corrosion, or damage.

•   Repair or replacement of damaged blades or vanes.

•    Restoration of blade profiles through machining or coating application.

Combustor repairs:

•   Inspection for cracks, warping, or carbon deposits.

•   Welding or replacement of damaged parts.

•   Cleaning and refurbishment of combustor liners.

Casing repairs:

•   Inspection for cracks, leaks, or thermal distortions.

•   Welding or patching of damaged areas.

•   Replacement of worn seals or gaskets.

 Bearing repairs:

•   Inspection for wear, misalignment, or lubrication issues.

•   Replacement of damaged bearings or seals.

•   Alignment and balancing to ensure proper operation.

Seal repairs:

•  Inspection for leaks or deterioration.

•  Replacement of worn seals or gaskets.

•  Application of sealing compounds or coatings.

Cooling system repairs:

• Inspection for blockages, leaks, or corrosion.

• Cleaning or flushing of cooling passages.

• Repair or replacement of damaged cooling system components.

Control system repairs:

• Inspection for malfunctions or sensor failures.

• Calibration or replacement of control components.

• Testing and validation of control system functionality.

Non-destructive testing (NDT):

•  Inspection for hidden defects using techniques like ultrasonic testing, dye penetrant inspection, or eddy current testing.

•  Identification of cracks, flaws, or material degradation without causing damage to the components.

Coating applications:

• Application of protective coatings to enhance corrosion resistance, thermal insulation, or erosion resistance.

• Surface preparation and coating application using methods such as thermal spraying or plasma deposition.

Performance testing:

• Verification of repaired components through performance testing under simulated operating conditions.

•  Monitoring of performance metrics such as power output, efficiency, and emissions to ensure compliance with specifications and standards.

Inspection and Assessment

•  Thorough inspection of turbine components for wear, erosion, corrosion, cracks, and other forms of damage.

•  Assessment of turbine alignment, clearances, and overall condition to identify areas requiring repair or replacement.

Blade and Rotor Repair

• Repair or replacement of turbine blades and rotors affected by erosion, corrosion, or mechanical damage.

• Restoration of blade profiles and surface finishes through machining, welding, or coating application.

Casing Repair

•  Welding or patching of turbine casing to address cracks, leaks, or structural damage.

• Replacement of worn seals, gaskets, and insulation materials.

Bearing and Seal Maintenance

• Inspection and refurbishment of bearings, including replacement of worn components and lubrication systems.

• Repair or replacement of seals to prevent steam leakage and maintain operational efficiency.

Governor and Control System Repair

• Inspection and calibration of turbine control systems, including governors and actuators.

• Replacement of malfunctioning sensors, valves, and other control components.

Rotor Balancing

• Balancing of turbine rotors to minimize vibration and ensure smooth operation.

• Dynamic balancing procedures to correct any imbalance and prevent damage to bearings and other components.

Steam Path Inspection and Cleaning

• Cleaning of steam paths and internal components to remove deposits, scale, and other contaminants.

• Inspection of steam path components such as nozzles, diaphragms, and labyrinth seals for wear and erosion.

Non-Destructive Testing (NDT)

• Use of NDT techniques such as ultrasonic testing, magnetic particle inspection, and dye penetrant testing to detect hidden defects and cracks in turbine components.

Coating Applications

• Application of protective coatings to turbine blades, rotors, and casings to enhance corrosion resistance, erosion resistance, and thermal insulation.

Performance Testing and Commissioning

• Verification of turbine performance through testing under simulated operating conditions.

• Monitoring of key performance metrics such as power output, efficiency, and steam consumption to ensure optimal turbine performance after repair and maintenance activities.

Effective steam turbine repair procedures are crucial for maintaining operational reliability, efficiency, and safety in various industrial applications where steam turbines are utilized.

Inspection and Assessment

• Comprehensive inspection of compressor components, including impellers, casings, bearings, seals, and shafts, to identify wear, corrosion, cracks, or other damage.

• Non-destructive testing (NDT) techniques such as ultrasonic testing, magnetic particle inspection, and vibration analysis to detect hidden defects and assess structural integrity.

Disassembly

•  Careful disassembly of the compressor, ensuring proper handling to prevent further damage to components.

• Removal of impellers, bearings, seals, and other internal parts for inspection and repair.

Component Repair or Replacement

• Repair or replacement of damaged or worn impellers, diffusers, casings, and other compressor components.

• Machining or welding to restore worn surfaces, rebalance impellers, and repair cracks or deformities.

• Replacement of worn bearings, seals, and gaskets to ensure proper sealing and lubrication.

Balancing

• Dynamic balancing of impellers and shaft assemblies to minimize vibration and ensure smooth operation.

• Precision balancing to meet manufacturer specifications and reduce wear on bearings and seals.

Clearance Adjustments

• Adjustment of clearances between impellers and casing, as well as between impellers and diffusers, to optimize compressor performance and efficiency.

•  Machining or shimming to achieve proper clearances and prevent rubbing or contact between rotating and stationary parts.

Shaft Alignment

• Alignment of compressor shafts and bearings to minimize misalignment-induced vibration and ensure reliable operation.

• Laser alignment techniques to achieve precise alignment and minimize shaft deflection.

Seal Replacement and Upgrades

• Replacement of worn or damaged seals, including labyrinth seals, oil seals, and gas seals.

• Upgrades to advanced sealing technologies to improve efficiency, reliability, and leakage control.

Testing and Performance Verification*:

• Functional testing of the repaired compressor to verify proper operation, including startup, shutdown, and performance under various operating conditions.

• Performance testing to measure flow rates, pressure ratios, power consumption, and other key performance parameters.

• Monitoring of compressor operation and performance during commissioning to ensure reliability and efficiency.

Centrifugal compressor repairs require specialized expertise in compressor design, metallurgy, machining, and precision engineering. Properly executed repairs are essential for maximizing compressor reliability, efficiency, and service life in industrial processes.