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Turbine Services
- Outages
- Inspections
- Field services
- Long-term service agreements
UNEW Industries plans and executes the maintenance of gas turbines and steam turbines: the planned outages at which parts are exchanged, the inspections that decide what is exchanged, the field crews that do the work, and the long-term agreements that put all of it on one schedule with one supplier.
We are a parts manufacturer and a repair workshop as well as a service company. The parts installed at our outages are our own, made to our own technical data, and the parts removed go to our workshop for refurbishment. One contract covers the outage, the parts and the repairs, and one team is accountable for the unit going back on line on the planned date.
What We Do
| Service | Scope |
|---|---|
| Outage services | Combustion, hot gas path and major inspections on gas turbines; minor and major overhauls on steam turbines; generator support — planned, forced and emergency. |
| Inspection services | Borescope, non-destructive examination, dimensional and metallurgical inspection, rotor assessment, control system audits and performance testing — on site and in our workshop. |
| Field services | Technical direction, supervision and skilled crews for any scope of turbine work, with tooling, from a single specialist to a complete outage team. |
| Long-term service agreements | Multi-year agreements covering outages, parts, refurbishment, inventory and engineering support for one unit or a fleet. |
Outage Services
We execute the complete inspection cycle of the unit as a turnkey scope or as any part of it — technical direction only, parts and technical direction, or the full outage with our own crew, tooling and parts.
Gas Turbines
| Inspection | Scope of work | Parts exchanged |
|---|---|---|
| Combustion inspection (CI) | Open the combustion system; inspect and exchange combustion hardware; borescope the turbine and compressor; check fuel nozzles, cross-fire tubes and flow sleeves; close and test | Combustion liners, transition pieces, fuel nozzles, cross-fire tubes, seals, gaskets and inspection consumables |
| Hot gas path inspection (HGPI) | CI scope plus removal of the upper turbine casing; inspect and exchange turbine nozzles, buckets and shrouds; inspect wheel-space, seals and bearings; clearance and alignment record; close and test | Complete hot gas path set — nozzles, buckets, shrouds, ring segments, seals — plus the CI kit |
| Major inspection (MI) | HGPI scope plus removal of all casings and the rotor; full compressor and turbine inspection; rotor NDE and dimensional record; bearing, coupling and casing inspection; alignment; reassembly and test | Hot gas path and combustion sets, compressor blading as found, bearings, seals and all major-inspection consumables |
Steam Turbines
| Inspection | Scope of work | Parts exchanged |
|---|---|---|
| Minor inspection | Valve and steam-chest inspection, bearing inspection, governor and protection system check, clearance record without opening the main casing | Valve internals, bearings, packing and gaskets as found |
| Major overhaul | Open the casing, remove the rotor; blade, diaphragm and seal inspection; rotor NDE and run-out; casing and bolting inspection; alignment; reassembly and test | Blades, diaphragms, labyrinth and packing seals, bearings, bolting and consumables as found |
| Generator | Rotor removal and reinstallation, stator and rotor inspection and electrical testing, bearing and seal work, in support of the turbine outage | Bearings, hydrogen seals, brushes and consumables as found |
How an Outage Runs
| Phase | What we deliver |
|---|---|
| Planning | Scope of work, parts and consumables list, tooling list, crew plan, day-by-day schedule and risk review, agreed with the plant before mobilization |
| Mobilization | Parts, tooling and crew on site before the unit comes off line; pre-outage borescope and performance baseline |
| Execution | Disassembly, inspection, parts exchange and reassembly to the agreed schedule, with a daily report to the plant |
| Testing and return to service | Alignment and clearance record, start-up support, load test, vibration and performance check, tuning |
| Close-out | Outage report — findings, measurements, parts installed and removed by serial number, open items and recommendations for the next interval |
Parts removed at the outage are inspected on site, classified for repair and shipped to our workshop, so the refurbished set is ready before the next interval. Forced-outage response is available under our service agreements with a defined response time.
Inspection Services
Inspections are carried out on the installed unit, on removed components at site and in our workshop. Every inspection is delivered as a report with findings, measurements and a recommendation.
| Inspection | Scope |
|---|---|
| Borescope | Compressor, combustion and turbine sections through the standard access ports; pre-outage, interval and post-outage inspections with photographic report and check sheets |
| Non-destructive examination | Fluorescent and dye penetrant, magnetic particle, eddy current, ultrasonic and phased-array examination of blades, discs, rotors, casings, bolting and welds; certified NDE technicians |
| Dimensional and coating | Airfoil, tip, root and seal dimensions, clearances, coating and wall-thickness measurement against the drawing and service limits |
| Metallurgical | Coupon sectioning, microstructure, hardness and coating evaluation to establish the condition of the base alloy and the remaining life of the set |
| Rotor assessment | Rotor NDE, run-out and bow measurement, disc and bore inspection, balance; remaining-life assessment of rotors approaching their design life |
| Control system audit | Health audit of the turbine control system — hardware record by part number, revision and serial number, I/O, software and configuration, HMI and network, alarms and protection, spares |
| Performance | Load and heat-rate testing, wheel-space and exhaust temperature spread analysis, cooling-flow investigation, compressor performance and fouling assessment |
| Condition monitoring | Vibration analysis, remote condition monitoring and diagnosis of the unit between inspections |
| Root cause investigation | Instrumentation faults, premature part deterioration, material and fuel effects on part life, forced-outage events |
Incoming inspection of removed parts classifies each part as light, medium or heavy repair, with every classification anchored to measured values, and identifies before any work begins the parts that are not economical to repair.
Field Services
Our field crews are the crews of our own outages. They are available to the plant for any scope of work, under our direction or under the direction of the plant.
Personnel
| Role | Function |
|---|---|
| Technical field advisor | Technical direction of the outage, OEM-level procedures, clearances and acceptance criteria, final sign-off |
| Outage manager and shift supervisors | Schedule, crew, tooling and parts control, daily reporting, interface with the plant |
| Mechanical technicians and millwrights | Disassembly, inspection, parts exchange, reassembly, alignment |
| Welders and machinists | Site welding, on-site machining of casing joints, bolting and seal surfaces |
| Electricians and I&C technicians | Instrumentation, control system, generator and auxiliary electrical work |
| NDE technicians | Certified penetrant, magnetic particle, eddy current and ultrasonic examination |
| Riggers and crane operators | Casing and rotor lifts, heavy-lift planning and execution |
Specialized Field Work
| Service | Scope |
|---|---|
| Rotor removal and installation | Gas turbine, steam turbine and generator rotors, with lift plans, fixtures and cradles |
| Alignment | Casing, bearing and coupling alignment; internal alignment of compressor discharge casing and turbine shell; laser and optical methods |
| Field balancing | In-situ balancing of turbine and generator rotors after outage or on vibration complaint |
| On-site machining | Casing horizontal joints, bearing housings, coupling faces and seal fits machined in place |
| Control system services | Fault resolution, tuning and combustion optimization, card replacement, software and configuration changes on the turbine control system |
| Start-up and commissioning | Post-outage start-up, load test and tuning; commissioning support for new installations and relocated units |
| Forced-outage response | Rapid mobilization of a technical advisor and crew, with parts from our inventory, to bring a tripped unit back on line |
| Tooling | Complete outage tooling sets for the frames we support, or supplementary tooling for the plant's own crew |
Long-Term Service Agreements
A long-term service agreement puts the maintenance of the unit on one schedule with one supplier. Outages, parts, refurbishment and engineering support are planned years ahead, and the plant knows its maintenance cost and its parts lead times before the budget year begins.
What the Agreement Covers
| Element | Scope |
|---|---|
| Maintenance plan | Multi-year outage schedule by equivalent operating hours or starts, updated every year with the plant's actual operation and dispatch profile |
| Outages | All planned inspections in the term — technical direction, crew, tooling and execution — with fixed outage durations |
| Parts | Capital parts, consumables and operational spares for every planned inspection, at fixed prices and fixed lead times for the term |
| Refurbishment | Removed sets repaired in our workshop and returned before the next interval; repair levels and work volume stated task by task |
| Inventory | A spare set held for the client in UNEW inventory, so the unit is never waiting for parts |
| Engineering support | Borescope and interval inspections, control system audits, performance monitoring, root cause investigation and technical advice throughout the term |
| Forced-outage response | Defined response time for a technical advisor, crew and parts on an unplanned event |
| Reporting | Outage reports, refurbishment reports and an annual condition report on the unit |
Agreement Structures
| Structure | Coverage |
|---|---|
| Full scope | Outages, parts, refurbishment, inventory, engineering support and forced-outage response — one contract for the maintenance of the unit |
| Parts and technical direction | Parts, refurbishment and a technical field advisor for each outage; the plant provides the labor |
| Parts frame agreement | Fixed prices and lead times for parts and refurbishment over the term, with outages quoted event by event |
Pricing is agreed per fired hour or equivalent operating hour, as a fixed annual fee, or per event, to match the plant's operating profile and budget. Availability, outage duration and response-time commitments are written into the agreement. Terms typically run from one inspection cycle to the life of the unit.
Fleet Coverage
| Machine | Coverage |
|---|---|
| Gas turbines | GE heavy-duty E- and F-class frames including 6F, 7F and 9F; Siemens V94.2 / SGT5-2000E and V84.2; GT13E2; Solar; other makes on request |
| Steam turbines | Industrial and utility steam turbines of all major makes — see the Steam Turbines page |
| Generators | Turbine-driven generators, in support of the turbine outage |
Track Record
Long-term service agreements on Siemens V94.2 fleets in Egypt, Argentina and the United Arab Emirates — hot gas path inspections, capital parts and refurbishment across compressor, combustion and turbine sections.
GE 6FA units in Vietnam since 2017 — combustion and hot gas path parts, refurbishment, hot gas path inspection outages and control system audits under a long-term service agreement; accepted alongside the OEM by Vietnam's power and refinery operators.
Hot gas path inspections executed as turnkey outages — planning, parts, crew, execution, testing and acceptance — for power producers and refineries in Southeast Asia, the Middle East, North Africa and South America.
Refurbishment programs of more than 2,000 serialized components per engine, with turbine vanes and blades returned to service through successive 33,000 EOH intervals.