Sucess Stories
Foster Wheeler Zack, Inc.
ECM has provided millright centerline and machining services for the installation of the Seimens
Westinghouse combined cycle, 2 gas turbine, 1 steam turbine, contracted
for Foster Wheeler Zack at PP&L's Martins Creek generating facility.
Arthur Kill Station
ECM successfully provided project management, craft manpower, tooling and machine shop support to overhaul Units
#2 and #3. This work included Turbine valve inspections, Boiler Feed Pump Turbine overhaul, reduction gear
re-alignment, bearing inspections, coupling re-alignment, and Boiler Circ Pump replacement.
Our satisfied customer statements included,
"everything was well planned"
"the machine came apart like it had a zipper"
"well organized"
"the machines have never run so well"
ECM's most recent major steam turbine turnkey overhaul was at Joliet Station #8 this past spring. This was a Westinghouse cross-compound 580 MW unit in which we overhauled the HP Turbine, IP Turbine, HP Generator, LP Generator H2 Seals and bearings, valves and auxiliaries. Extensive off-site repair work was necessary after ECM's on-site grit blasting, NDE, steam path audit of components was completed. ECM's turnkey overhaul responsibilities included multi-craft project labor pre-job jurisdictional conference, ECM experienced project superintendents including parts supervisor, TFAs, one per shift, induction bolt heating, full component on-site and off shop repairs and machining, schedule development, update and projections, cost developments, and periodic update status reports. The IP rotor journals were ground and high speed balanced in HII's vacuum pit. Boresonic rotor inspection of the IP Turbine was conducted. Life assessment of the rotor was additionally conducted. ECM coordinated the numerous emergent component repairs recognizing schedule impact. ECM's turnkey abilities included rescheduling (utilizing Microsoft Project) all component assembly due to extensive repairs. ECM's laser alignment of the stationary steam path "Tops-On/Tops-Off" also incorporated bearing re-alignment in a parallel effort, minimizing critical path coupling re-alignment at final assembly. This was successfully completed within the original eight weeks time frame.
Joliet Station #7
ECM also completed the overhaul of both LP Turbines at MWGen’s Joliet Station Unit #7.
This included the 580 MW
Westinghouse 80 Ton LP Rotors, Valves, BFPTs, XOP Flange machining, Governor
controls, Minor Generator H2 seals inspection. Included complete turnkey services: On-site project
Management, TFAs, Superintendents, Multi-craft Labor, ECM portable Machine
shop, ECM portable Lathe, ECM machinists, Subcontractors and Tops On/Off
Steam Path Laser Alignment.
Hugo Station
ECM has successfuly completed a major steam path retrofit of the HP-IP and LP Turbines at Farmer's Electric
Cooperative Generating Station. The work included providing all tooling, craft manpower and supervision for
disassembly, machining, alignment and assembly of new ABB components in an existing 450 MW unit.
Hartwell Dam
ECM's Hydro work continues with recent Generator re-winds and refurbishments on four units at Hartwell Dam Hydro.
