Power Generation Services

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The best in Coupling Line Boring.
Misshaped bolt holes cause coupling vibration and can create serious schedule delays during the removal and installation of bolts. INTEGRA Coupling Services’ TRU-Bore™ Coupling Line Boring System provides the high-precision tolerances necessary to speedily correct these problems without having to remove the coupling for offsite machining. The proven cost savings generated by INTEGRA Coupling Services provide significant benefit, especially when they are related to critical path operations. The three main advantages of the TRU-Bore™ Coupling Line Boring System are:
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  1. The invaluable time savings that it takes to bore consistently accurate bolt holes on-site, boring through both halves of the coupling.  Instead of the typical full shift to bore a hole using conventional methods, INTEGRA can do it in less than two hours per hole.
  2. Because of the high precision of Coupling Line Boring machined holes, clients are now able to fully maximize the benefits that can be achieved with Hydraulic Bolts.
  3. The precision TRU-Bore™ machined holes also greatly facilitate the servicing and bolting operations on couplings that continue to use traditional bolts.
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ACCURATE

EXPERT TECHNICIANS

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SPECIALIZED

FAST

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Induction Bolt Heating
Reduce your outage times.

Utilizing our advanced induction bolt heating (IBH) technology, your outage time can be drastically reduced. Rather than spending over 40 minutes per bolt, our IBH technology can slash it down to 5 minutes. All the while keeping your asset and workers safe. The heating coils are cool to the touch and there will be no damage to your bolt threads with our industry proven techniques and equipment.

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ACCURATE

REDUCE DOWNTIME

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SAFE

FAST

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Turbine Closure System
Confidently determine clearances.

INTEGRA’s Turbine Closure System service replaces traditional time consuming bolting methods. To close the horizontal joint we apply a simultaneous load to existing shell fasteners using a series of specialized hydraulic load cells. The system requires no modifications to the turbine’s present bolting arrangement.

The load cells are simply and quickly installed onto the unit’s service studs and pressurized. This results in full flange-to-flange contact in a matter of minutes. The inner and outer shells can even be tensioned at the same time. On a typical 500-600 MW unit, the initial installation, pressurization and subsequent removal of an entire Turbine Closure System can often be completed in 2-4 hours.

As a result, Tops-On alignments which used to require two to three days to perform can now be done in a few shifts. The System is also often used to rapidly close horizontal joints during final reassembly of turbines, thus saving even more time.

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RAPID

CONFIDENT

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EFFECTIVE

QUICK

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INTEGRA Coupling Services focuses on turbine coupling issues and specializes in providing a complete package of services that are essential to properly managing the coupling maintenance process. INTEGRA Coupling Services has a single-minded focus on solving and preventing coupling problems, rather than merely fixing the symptoms.

With 25+ years experience of on-the-job experience, INTEGRA Coupling Services has been on the leading edge of several important industry developments.

Utilizing our customized and portable TRU-Bore™ Coupling Line Boring System, we provide the highest precision tolerances and bolt hole finishes needed to eliminate improperly shaped holes which cause coupling vibration and can create serious schedule delays during the removal and installation of bolts.

Installation & Removal of Coupling Bolts
Hydraulic Radial-Fit Bolts.

INTEGRA Coupling Services has been a key player in the development, servicing, training and installation of Hydraulic Radial-Fit Bolts. The hydraulic coupling bolts overcome many of the problems associated with conventional coupling bolts and quickly help to re-establish coupling concentricity. Proper machining of coupling holes and sleeves are vital for efficient assembly and disassembly of hydraulic coupling bolts.

Coupling holes and bolt assemblies are uniquely marked to ensure each bolt assembly is installed in its corresponding hole in a sequence that reduces the number of shaft rotations, with the sleeve properly positioned in the hole in the correct position, and the bolt clamp force tension properly applied without damage to the coupling assembly the process is completed in a safe and productive manner.

Disassembly can usually be accomplished using the oil injection process for ease of bolt removal or, in some situations, a combination of oil injection and use of tensioning equipment is needed. Knowledge of these combined methods is critical to prevent schedule creep, avoid damage to the assembly while maintaining a safe work environment. Once bolt assemblies have been removed each part and bolt hole is inspected, conditions found documented, and repairs made as necessary prior to reassembly.

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COUPLING CONCENTRICITY

MAINTAIN SAFE WORKPLACE

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AVOID PROJECT CREEP

REDUCE EQUIPMENT DAMAGE

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Onsite Sleeve & Bolt Machining
Absolute precision.

Line bored coupling holes are only as good as the preciseness of the hydraulic bolt sleeve or fitted bolt to be installed.

Using our on-site lathe, hydraulic coupling bolt precision sleeve machining brings together the close tolerance relationship between the hole and the sleeve to provide effective application of the hydraulic coupling bolt system.

Where fitted coupling bolts are used this same level of precision machining applies to provide the proper clearances needed between the coupling bolt and coupling hole.

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ACCURATE

ON-SITE

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SAFE

EXPERT TECHNICIANS

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Sling Rod Analysis
Properly distribute your loads.

Incorrectly loaded sling rods can cause a number of problems including permanent deformation, tube weld cracking, shortening the life of the boiler, and catastrophic failure. For decades, INTEGRA has offered individual attention to detail to assure accurate loads in sling rods.

Individual weighing of the hanger roads with the boiler in either a hot or cold condition allow the service to be adaptable to your needs. Completed on a per rod basis, loads are recorded in both tabular and graphical form. Based on the testing results, optimal balancing will be achieved by redistributing the loads in complete rows.

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ACCURATE

COMPLETE REPORT

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SAVES TIME

BALANCE ANY SIZED BOILER

Pipe Support Rod Services
Optimize your assets.

High thermal cycling of a Power Generation Unit means variable support loading and stresses to the piping. Possible permanent creep deformation, reduced system-operating life and other major failures are avoidable by utilizing INTEGRA’s Pipe Support Rod Services in order to optimize the success and life expectancy of the plant.

Loads are verified at all hanger locations and the information obtained determines whether the design load matches the pipe load at each hanger location. This process is completed with a certificate of accuracy of the unit.

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PREDICT SYSTEM WEAKNESS

PREVENT FORCED OUTAGES

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AVOID ACCIDENTS

REDUCE EQUIPMENT FAILURE

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