Power Plant Services - STEAM TURBINE ENGINEERING …steamturbineindia.com/images/PPS Manufacturing...

Power Plant ServicesISO 9001:2008 Certified24/7 Service - Turbine Parts - Valve Inspection/Repair - Blades/Buckets - Rotor Repair - Reverse Engineering

“A Part Of The Solution”

Alin Machining Company, Inc (d/b/a Power Plant Services) is a one stopaftermarket Turbine, Generator, Valve and Coal handling equipment partsmanufacturer and 24/7 repair facility.

MissionConsistently provide our customers with products and services to theircomplete satisfaction in terms of Quality, Competitive Pricing and ExpeditedDelivery.

Strengths• Emergency Service - 24 Hours, 7 days Per Week• Manufacturing of Valve Parts/Blades Using Knowledgeable Staff• Rotational Equipment Repair• Valve Inspection/Repair/Restoration• Reverse Engineering Expertise• Project Management Services• ISO 9001:2008 Certified

Facility• 75,000 sq.ft. of Machining Space with 65 plus machinists• 18 CNC Machines, Lathes/Mills/Grinders,EDM’s & Gun Drilling, Water Jet,

Hardness/Finish Tester, Material Analyzer• 4-7 1/2 ton O/H Cranes & 1-10 ton O/H Crane with height clearance of 28 ft• Sandblasting Capability (22’W x 13’H x 40’L)• 4 Weld Booths, TIG,MIG, Plasma Capability• Tool/Parts Crib, Standard Fasteners, Valve Parts,Turbine Outage Items• Stress Relieving (7 Ovens)• Stock/Sell 422 SS, Incoloy, Alloy Steel, Other Strategic Materials

Power Plant Services3131 Soffel Ave.Melrose Park, IL 60160Phone: (708)345-8600Fax: (708)345-9181Email: [email protected]

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FastenersPPS is a major non-OEM supplier of Turbine Fasteners. Ourknowledgeable staff combined with an enormous supply ofstrategic materials, enable us to “respond quickly” to thecustomer’s outage requirements.

Our modern 75,000 sq ft. machine shop equipped withCNC machines enables us to efficiently turn around partsquicker than most other turbine parts suppliers. Our man-agement and craft personnel possess vast experience inthe turbine replacement parts business and together, pro-vide the skills for the quality and efficiency necessary inthis “fast turnaround” business.

Studs, nuts, bolts, pins, and washers are typical fasteneritems that we have been providing the utility and industrialmarket for years.

If we can’t identify a part number, our full time ReverseEngineering department can rapidly replicate a part to thesame precise dimensions using qualified turbine specifiedmaterials. A state of the art coordinate measuring machine(CMM) and an in-house metallurgical analyzer are just twoof the precise instruments used by our staff.

If you want a replacement part manufactured fast, callPower Plant Services with your requirements.

POWER PLANT SERVICES 3131 Soffel Avenue Melrose Park, IL 60160 Phone (708) 345-8600 Fax (708) 345-9181 www.ppsvcs.com



03/09

Valve Parts

• Stems• Bushing• Strainers• Bypass Discs (stellited)• Cross Heads

Power Plant Services has established itself as one of themajor non-OEM facilities of manufacturing and repairingsteam turbine valve parts.

Our specialty is “quick turnaround” service. Power PlantServices offers complete inventories of strategic materialswith seven days-around the clock coverage. Power PlantServices employs more than 65 machinists. The combinationof materials and personnel allows us the opportunity toprovide quality parts with fast delivery.




03/09



Power Plant Services has inspected, repaired and manufacturedparts for almost every type of turbine valve.

• Control

• Intercept

• Throttle

• Main Stop

• Reheat/Combine Reheat

• Governor

• Blow Down

• Ventilator

Turbine Valve Assembly Repair


03/09



Turbine Valve Assembly RepairFor over a decade, Power Plant Services has serviced (disassemble, repairand assemble) turbine valve assemblies for more than 60 power plants.

We have extensive experience with valve assemblies for stations rangingfrom 50mw to 900mw turbines of various brands, such as GE,Westinghouse, Allis, etc.

PPS has more than 100 years of cumulative managerial turbine valve expe-rience and an equally trained work force, extensively experienced in theturbine valve repair craft.

We are a completely integrated valve maintenance facility, which includesthe following capabilities:

• Inventories of strategic materials (422 SS, Nitralloy, Inconel, B16, 1-1/4 Chrome-moly-vanadium bars and forgings, austenitic stainlesssteels, etc.)

• Parts identification capabilities with the ability to reverse engineer.

• Necessary CNC and manual machine tools, with highly skilled ma-chinists working a 24/7 schedule.

• Manufacturing & repair in the same facility reduces the leadtime andcost.

• Dedicated project engineers on each project, responsible for in-process coordination with the customer.

Advantage of outsourcing assemblies:Outsourcing of valve assembly, evaluation and repair scope allows UtilityMaintenance Departments to use their key and limited personnel on tasksother than valves; thereby increasing the overall efficiency of the availablemanpower.

Repair projects that are performed off-site in an experienced turbinemachine shop has better control of the quality aspects of the repair scope.A valve evaluation and repair, that is treated as a “precision machining task”and carried out as such, will give the customer a higher probability ofminimizing forced outages and enable the plant to maximize expected valveperformance intervals.


03/09

Welding Services

PPS provides welding services for repair of various turbinecomponents including valve seats, discs, bypass discs, strainers, etc.

Hard face welding is used to extend the life of the differentcomponents, i.e., Shafts, Steam Turbine Blades, Diaphragms andNozzles. PPS capabilities include various welding processes such asShielded Metal Arc (SMAW), Gas Metal Arc (GMAW), Gas TungstenArc (GTAW) and Plasma Transfer Arc (PTA).

At Power Plant Services, we offer a long term solution to your repairrequirements.




03/09

Blade Manufacturing

PPS has a state-of-the-art Blade Manufacturing Facility within our existing plant.PPS takes pride in providing 24/7 technical support, engineering and manufac-turing. Our team of engineers, programmers and machinists will provide expertassistance with all of your blade requirements.

Engineering: Extensive turbine experience gives us an edge on our competi-tors; we can work from your sample parts, prints/specifications, or recommendspecification and designs/redesigns. In the field or in house, we can cover allyour needs.

Manufacturing: We manufacture blades of all makes and models from initialCAD/CAM design to our CNC machining.

PPS Blade manufacturing capabilities include:

• Airfoils from 1 to 30 inch• Integral Shroud• Angled Tips• Finger Root• Ball Root• Internal or External Root• Tie Wire Holes• Straight or Twisted• Mid Spans• Tenon (Multi Tenons)• Dovetail Root• T & Double T Root• Axial Entry• Tangential

We will provide you with the highest level of job satisfaction. Let us make adifference.




03/09

Turbine Seals & PackingTurbine Seals & Packing

• J Seals• Flat Seals• Seal Rings (GE)• Pressure Seal Ring (Westinghouse)• Pressure Seal Ring (Allis)

PPS is a specialty manufacturer of J Strips, Packing Rings, Spill Strips andall types of conventional and specialty turbine seal requirements.

We have the engineering staff, CAD/CAM services and the ability toreverse engineer and create clearances to marry the rotational andstationary parts.

Complete Packing Box and Oil Deflector assembly repair is available inour 75,000 sq. ft. facility with complete crane coverage. Our capabilitiesinclude weld repair, machining of the Packing Boxes and Oil Defectorcasing followed by installation of in-house manufactured packing.




03/09

Erosion ShieldsPower Plant Services offers completely integrated stellite erosion shield supply.Our capability includes:

• Stocking of stellite sheets in 0.062 and 0.050 thickness• In-house shearing, bending and EDM wire cutting• Stocking of all brazing supplies such as fluxes and silver wire and ribbon

We offer competitive pricing with unmatched response and delivery time

”Finger” Dovetail Pin & Reamer ManufacturePPS can supply completely manufactured finger dovetail pins using in-housestock material.

Certified tool steels are used and the proper level of certified inspectionpersonnal carry out each individual Q.C. task.

Each group of pins is custom ground to “Field Specification”.

100% Quality Control inspection is maintained on each piece in a given lot (hard-ness, material chemistry and magnetic particle inspection) and complete trace-ability is maintained on each piece via dedicated QC personnel assigned to eachorder.

Miscellaneous HardwareWe stock reamers and can custom grind to suit/field installationrequirements. PPS also supplies L-O cover (Z-lock), punch & die, cover stock,etc.

LP Blade Tie Wire & Lashing Lug MaterialsMost standard size hollow and solid tie-wire material is maintained in stock, canbe cut to specified size and shipped rapidly.



“A Part Of The Solution” 03/09



• 4 Axis CNC Milling (vertical & horizontal 2 pallet)

• 4 Axis CNC Lathes (mill & turn) Live tooling

• 4 Axis Wire EDM

• Water Jet Cutting - 6 ft x 12 ft, up to 6’’ thick

• Gun Drill - 2’’ Diameter x 60’’ Long

• Twin Spindle Gun Drill - 1’’ Diameter x 36’’ Long

Additional “In-House” Services:

• Sandblasting

• Automatic Welding (TIG/MIG/Plasma/Sub-Arc)

• Surface Grinding

• OD/ID Grinding

• Honing


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Machining Capabilities




03/09

Engineering & Reverse EngineeringOur full time Engineering department can rapidly replicate a part to the same precise dimensionsusing qualified turbine specified materials.

State-of-the-art dimensional evaluation using precision measuring devices, including:

• Coordinate Measuring Machines

• Optical Comparator

• Portable FARO Arm

• Niton Material Analyzer

Strengths of our Engineering Department:

• Product Application knowledge

• Understanding of metallurgical properties

• Material certified through traceable documentation

CAD/CAM systems using SolidWorks,AutoCAD, and MasterCam




03/09

Large Machine Capabilities

Cincinnati Vertical Boring Mill90’’ OD Table, 100’’ maximum swing, 100’’ under rail, 57’’ head travel

Omba Vertical Boring Mill59’’ OD Table, 60’’ maximum swing, 69’’ under rail, 56’’ head travel

Shibura Manual Horizontal Mill32’’ spindle travel, 70’’ vertical travel, 155’’ horizontal travel,table size59’’ square, extended size 59’’x 118’’

G & L Manual Horizontal Mill32’’ spindle travel, 70’’ vertical travel, 70’’ horizontal travel, 108’’ crosstraverse, table size 60’’ x 120’’

Poreba Lathe60’’ swing x 15 feet length

Lucas CNC Horizontal Mill75’’ spindle travel, 100’’ vertical head travel, 94’’ table travel, GE Fanuc16M control

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