Power generation and petrochemical industries worldwide rely daily on a whole host of service and support companies to provide service to rotating machinery. Several large service, repair and overhaul companies currently compete in this arena, but many more smaller, specialty companies are also carving out their shares in the marketplace.

    Turbine Resources Unlimited (TRU), located in West Winfield, New York, U.S.A., is one such smaller player that has seen its business expand rapidly within it's first two years of operation. The company offers a range of on-site gas and steam turbine services, as well as in-house repair and overhaul services. Also, TRU is capable of applying specialty coatings for both hot section and compressor components.

    "With our component repair, coatings application, on-site field support and new and used spare parts acquisition services, it's easy to see that we cover the whole gamut of services that our customers require," said Bill Howard, president of TRU. "With our vast knowledge not only of component, but also of turbine engine dynamics, we are able to assist our customers with decisions that may be on the border or outside of hte OEM limits. Decisions like what type of coatings are really required for certain component or safely expanding the OEM servicability or repair limits for their components."

    Gas turbines that the company currently services include ABB Alstom Typhoon and Tornado TA & TB; all models of General Electric Frame 3, 5, 6 and 7; all models of Westinghouse 92M, 191, 251, 501; Rolls-Royce Avon; and Garrett units.     

    TRU's scope of service for repairs includes comprehensive component repairs, component inspections, coatings application and removal, metalography, repair consultations and new & used parts location.

    Field service operations include gas and steam turbine consultations, various turbine inspections (borescope, combustion, hot gas path), major overhauls, engine rebuilding and startup support.

    The company currently offers compressor lubricity and corrosion resistant coatings including its TRU-Flow 2000, a compressor airflow enhancing super lubricity coating system and TRU-Seal 3000, a high temperature compressor corrosion resistant coating. Plasma applied coatings include thermal barrier coatings, chrome and tungsten carbide hard-facing coatings, as well as abradable coatings.

    "By mid-summer 2000 we will have HVOF coating capabilties in place," said Howard. "This will provide an even better bond coat for our thermal barrier coatings, as well as allow us to apply the CoCrally - CoNiCrally & Mcrally type coatings that have become so popular with our customers."

    Among recent TRU accomplishments include several orders involving tight delivery scedules or unscheduled outages that necesssitated rapid turnaround times.

• In the midst of an unsceduled outage, a southwestern U.S. power company required an emergency overhaul of their GE Frame 7EA row one nozzle assembly. The complete overhaul was completed in four days and returned to service. The nozzle exhibited structural cracking and extensive craze cracking at the airfoil pressure side and along the fillets. Nozzle work scope included inspection, disassembly, cover removal and replacement, weld repairs to all cracking, blending a full solution and final age heat treament in vacuum and reassembly.
• During a sceduled outage, a southwestern U.S. power company required extensive repairs to its Westinghouse 501B unit. Repaired components included compressor diaphragms, combustion baskets, clam shells, transition pieces and rows one through four turbine blade lock plates. the compressor diaphragms were repaired and coated with TRU seal 2000 coating system, which produces a smooth surface to compressor airfoils, enhancing airflow through the compressor section and offering corrosion resisatnace and increased waterwash efficiency. All components were delivered ahead of schedule.
• Four modified hot gas path inspections were performed for northeastern U.S. independant power producers. During one of the outages, a fit up problem was discovered on the replacement row one nozzle. The problem involved an interference fit to the row one support ring. The TRU field service team completely disassembled the nozzle assembly on site and corrected the installation problem within 16 hours of discovery.

    "Our expansion plans for the next five years are to continue to grow the business, but to remain somewhat small and diversified in order to provide the quick response and personalized support that our customers demand. Small businesses within the power generation industry tend to have the flexibilty, as well as technical expertise that our industry demands," Howard explained. "We also intend to get involved with in-house engine overhauls on the smaller turbine units within the next two years."