Power Generator Components Repair
William A. Schmidt specializes in servicing and repairing power generator components such as
heat exchangers. In service, gasket faces, partition plates, and internal surfaces of heat exchanger parts erode, corrode,
and fatigue requiring repair usually during a turn-around. In order to meet the
delivery measured in hours and days, a "best practices" repair system that
stream-lines resources needed, provides effective communication, and eliminates
waste has been developed.
As a lean manufacturing facility, WAS takes steps with each client such as holding a proactive planning meeting,
identifying appropriate contacts, arranging for efficient transportation, sharing proper documentation,
methods of eliminating chlorides, quality inspection and "Certificate of
Compliance", and communicating with a spread sheet identifying process steps and
estimated times to complete.
Proactive Preparation
In order to be successful, it is essential to get information and commitments well in advance of the
turnaround. The more information obtained upfront will result in less confusion
during the turn around. The importance of this proactive preparation is critical
to the success of the repair of the heat exchanger parts.
The basic information required six months in advance of the turn-around are the detailed schedule
including specific oil out and oil in dates, tentative identification
of the heat exchanger equipment needing repair, and a list of key turn-around
contacts in planning, quality/reliability, and purchasing.
The most important piece of information to get at this time is a clearly defined
and approved best practice scope of work from the refinery.
Best Practices Scope of Work
Normally the repair company is responsible for transporting
exchanger components back and forth to and from the refinery. Depending on the
volume of parts, it would be more effective to drop a trailer in an assigned area
on a designated [eight, ten, twelve hour] shipping cycle. If the volume is low or uncertain,
a stake body can respond on an as needed basis. The refinery’s assigned representative will be
responsible for loading and unloading the equipment.
All components should be marked or tagged by designated
refinery representatives before they leave the refinery to maintain the part identification through all
processes. These tags should be metal stamped to resist damage during blasting.
Once the components reach the repair facility, they are
identified with the preliminary list. If they are new parts they are added. Time
should be taken to confirm that a current work scope, ASME data sheet, and
drawings are available or on file.
The part is then taken to be blasted. The blasting should remove the original
coating and any mill scale. Immediately following the blast, the part is
washed with an appropriate solution to eliminate chlorides. Following the blast and wash stage the
part is examined for any subtle indication not originally observed. The work scope is then verified.
The next step of the process is the make the needed
mechanical repairs. All repairs will be done in accordance with the National
Board Rules & ASME code. The refinery is to provide applicable U-1 data sheets
and specific direction as to the applicable rules and code. Any partition plate replacement
will be done with mill test report certified SA-516-70 material.
The desired result is to restore the heat exchanger
part to its originally manufactured condition. Upon the completion of the machining, a
formal ASME code inspection and final quality inspection by repair facilities
quality representatives are performed. Then the parts are transported back to the refinery.
WAS General Procedures
WAS has procedures that protect both the customer and the company from
misinformation and misunderstanding.
- Fabrication standards established
- Preliminary concept sketch and/or work scope obtained
- Material specifications, grades, & schedules provided
- Concept information is confirmed for layout and bill of material
- Material specifications, grades, & schedules confirmed
- Formal purchase or service order issued
- Final drawing or work scope formally released for fabrication
- All process specifications planned and scheduled
- All “hold points” defined and scheduled
- Uninterrupted fabrication commences
- Any change to the order after this point places the job on hold.
- Formal written changes are made and a revised purchase or sales order is submitted to the customer for
approval
- Order is submitted to the customer for approval
On all rush jobs, a labor, material and subcontracting
estimate is made. This identifies critical milestones and provide a benchmark
for scheduling the job. Again this gives us a plan to work from to form a
schedule and hold ourselves accountable to the time.
Our goal is to serve our customers better than any other
metal working company. Identifying the real needs of the client is not always obvious. Negotiating
price, material substitution, and delivery within realistic limits and
boundaries can help reduce the waste associated with an unrealistic committment and.
make sure what we agree to is possible.
If more information is needed or you have questions regarding our power generator components
repair services, please contact us so we may assist you.
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