Case Studies

A 17MW Geothermal steam turbine had a persistent casing half joint leak recurring across three outage cycles. ProGen's root cause analysis identified exhaust casing distortion as the cause, and a targeted repair procedure returned the turbine to service leak-free.

The 320 MW HTC unit was shut down following restricted valve movement, revealing the chest seat had come adrift and caused significant damage. ProGen identified the root cause and delivered a fully customised seat redesign, restoring valve function and addressing weaknesses in the original OEM design.

A 250MW CA Parsons turbine IP cylinder was opened for inspection to find severe shroud separation across rotating and stationary blade shrouds. With re-blading ruled out due to cost and spares availability, ProGen proposed and engineered an innovative weld repair — a first of its kind carried out in New Zealand.

The 20MW bi-turbine units were suffering from a higher than expected bearing failure rate, with alignment suspected as the primary cause. ProGen conducted a photogrammetry study identifying four distinct phenomena, all contributing to the turbines running outside of alignment specification.