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

104Sales & Service

Locations Worldwide

Products Sold in Over

52 Countries

$8.6Billion 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

TurnkeyOutage

Managementby

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 OfficeRTS Repair FacilitySullivan, Missouri

U.S. Branch OfficeRTS Manufacturing Facility

Houston, Texas

RTS Latin American OfficeMedellin, 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 FacilityRTS 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 onthe delivery of OEM-quality services to its customers

PresidentPaul “Tim” Weiss

Senior ManagementCEO

Mitchell Lardner

Executive Vice PresidentDon Haag

Sales/ Marketing ROCC RGEN

ROCC/RGEN Operations

Manager

Marketing

Sales

Key Account Management

RGENDivision Leader

ROCCDivision Leader

RepairsManufacturingFuji RTS Columbia

Operations Manager

Operations Manager

Operations Manager

Vice PresidentHomero Garcia

Field Repair Division

Field Repair Operations Manager

CFOYoshimi Meya

Accounting

Administration Division

Human Resources IT

Chief Technical Consultant

Ed Campbell Sr.

LatinAmerica

HoustonFacilities

SullivanFacilities

Management and EngineeringManagementWill Surman, ROCC-RGEN Operations Manager22 Years of industry experienceOEM Trained, GE

Ronnie Duncan, ROCC Field Service Manager23 Years of industry experienceOEM Trained, GE, Siemens & Westinghouse

Greg Duncan, ROCC Supervisor13 Years in the business and IndustryOEM Trained, GE, Siemens & Westinghouse

Marshall Duncan, ROCC Supervisor11 Years in the business and IndustryOEM Trained, Siemens & Westinghouse

Ben Irvine, RGEN Operations Manager23 Years in the business and IndustryOEM Trained, GE

Mike Valdes, Generator Specialist10 Years in the business and Industry

Amanda Stamper, Controls Administer10 Years in the business and Industry

Shawn Browning, Repair Field Service Manager17 Years of industry experience

Al Wizeman Sr, Repair Facility Operations Manager29 Years of industry experienceOEM Trained, GE & Westinghouse

Todd Magnuson, Rotor Repair Facility Foreman 24 Years of industry experienceOEM Trained, GE

Matt Cole, REM Operations Manager11 Years in the business and Industry

Donnie Cullers, REM Production Manager11 Years in the business and Industry

David Mata, REM QMS18 Years in the business and Industry

Ricardo Ibanez, South America Operations Manager10 Years in the business and Industry

EngineeringDon McNelly, PE, Corporate Engineering9 Years of industry experienceOEM Trained, Toshiba

Charlie Wolfe, RGEN Director of Engineering19 Years in the business and IndustryOEM Trained – GE, Siemens & Westinghouse

Brian Biggins, Repair Engineering3 Years in the business and Industry

Jeff Sowden, REM Engineering11 Years in the business and Industry

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 HealthAsbestos

Hexavalent ChromiumLead

Fall ProtectionConfined SpaceHousekeeping

Electrical Safety RequirementsMaterials Handling Procedures

Lock Out Tag OutPPE

Power and Hand ToolsIndustrial Vehicles

Accident and Incident ReportingWelding Hot Work

Fire ProtectionHazard 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

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 3Minor Inspection – with

Generator Rotor in placeMajor Inspection with

rotor out, limited testingMajor 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

Generator Services Toolkits

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 WeldingAutomatic 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

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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