Schulz Electric Hydroelectric

Hydroelectric Services Turnkey Services and Maintenance Programs

24-Hour Emergency Service

Schulz Group’s hydroelectric specialists at Maine Industrial Repair provide comprehensive maintenance programs and repair services for hydroelectric generation facilities. Our experience can help minimize downtime, reduce annual maintenance expenses, and prolong the life of hydroelectric equipment. Schulz Electric and Maine Industrial Repair Services are ISO 9001:2008 Certified. Schulz Group’s attention to detail and quality standards are second to none in the industry. Now part of the Timken Company, Schulz Group is dedicated to expanding its proven reputation as the leader in hydroelectric generator services.

Schulz Group offers complete services for both horizontal and vertical units.

Schulz Group has the capability to service customers’ equipment, from On-site crews disassemble a generator waterline to exciter, as well as controls, switchgear and mechanical parts. prior to repair.

Industries served

• Waste Water Treatment • Municipalities • Hydroelectric Power Generation

• Fresh Water Treatment • Building Maintenance • Nuclear Power Generation

• Manufacturing • Schools and Universities • Engineering Support

• Paper Mills • Power Generation • Renewable Energy Applications

On-site inspection of a generator as part of a On-site inspection of a horizontal unit Technicians have the capability to perform complete preventive maintenance program. prior to mechanical repairs. in-place repairs to generator coils and poles.

Do you know the true cost commitment to customers and plays • Complete mechanical inspections of unplanned downtime? a vital role in providing solutions of guide bearings, head covers, designed to return equipment to linkage eccentrics, wicket gates, How long can you go without your like new condition. water bearings, runner cavitation, most critical units? Schulz Group and shaft alignment. will design and implement preventive Our programs include: maintenance programs for your facil- • Complete inspection of power- ity. Each maintenance program is • Complete inspection and testing of house, trash rakes, head gate customized to fit specific needs and the generator including insulation and penstock. offers 24-hour emergency service. resistance, volt-drop, PI, hi-pot, The end result is lower overall costs, power factor and EL CID testing. • Full switchgear services include increased uptime and a dedicated performing electrical testing and • Maintenance technicians will maintenance on circuit breakers, service provider supporting you inspect brushes, brush holders, every step of the way. transformers, cables and air gaps, commutator, slip rings protective relays. From motors and generators, to and wedges. gearboxes and switchgear, Schulz • Installation of thermal sensors, Group offers a full suite of repair, vibration sensors, proximity upgrade, service and maintenance sensors and positioning trans- solutions. Our ISO 9001:2008 ducers on critical components certification is part of our ongoing for local or remote monitoring.

Technicians preparing for switchgear and breaker maintenance at customer site. Completed and reassembled generator.

Technician taking winding data prior Pole piece reinsertion and reconnection Core loop test shows core degradation to stripping and rebuild. after service and rewind. prior to restack and rewind.

Schulz Group technicians utilize Rotor Predictive and their experience and knowledge to Diagnostic Services provide high quality rotor field coil • Complete field pole rebuilds rebuilds, stator rewinds and core Predictive maintenance can help avoid • Cleaning and testing rotor iron restacks, including uprates catastrophic failures and reduce down- assembly and coil redesigns. time by identifying machines near • Wedge tightness survey/drop test failure, or by monitoring a machine’s Stator performance over time. • Wire and laser alignments of • EL CID and/or core loop testing rotor and bearings Infrared thermography • Complete restack of core Other electrical services Infrared thermography can provide laminations early warning of problems with critical • Complete exciter overhauls equipment before catastrophic failure. • Rewinds including high voltage and rebuilds By identifying overheating electrical coils connections and other machine com- • Armature and field rewinds • CO2 dry ice cleaning ponents, repairs can be scheduled to minimize downtime. (cryogenic cleaning) • Full switchgear services Vibration trending and analysis • Stator uprate and coil redesigns • Startup services including phase ins • Repairs meet or exceed all Vibration analysis and trending is a IEEE standards method of evaluating current machine condition and monitoring a machine’s changes over a period of time. It can also be used to pinpoint a source of several problems such as misalignment, imbalance and bearing issues.

On-line motor testing

This in-service motor analyzer takes the next step in providing complete predictive and preventive maintenance programs. It provides root cause analysis through the separation of mechanical and electrical issues and is designed to pinpoint the challenges that rotating machinery faces. New stator core shown prior to rewind, and after successful restack.

Refurbished runner as part of a Large runner being balanced Bearing repair services available for thrust, mechanical rebuild. in-house after repair. water and roller bearings, with additional remanufacturing capability through Timken.

• Keyway damage repair Schulz Group offers a complete On-Site Services range of mechanical services for • Balancing services the hydro industry such as repairs Many times, repairs and maintenance to runners, wicket gates and • Complete bearing services services can be performed on-site head covers, as well as complete with little or no disassembly required. bearing repair services. • Wicket gate, curb rings and This allows production to stay at a head cover rebuilds maximum while downtime is held to Our extensive machine shop an absolute minimum. has the capability to completely • Shaft fabrication rebuild Kaplan and Francis runners. • Dynamic balancing and laser align- • Field machining We also repair cavitation holes, ment are applicable on all rotating equipment and will reduce vibration, keyway damage and balance • Metal stitching equipment up to 60,000 lbs. resulting in increased bearing life • Welding services and a smoother running unit with Services include: fewer breakdowns. • Keyway broaching • Runner repairs • Lead and asbestos removal provided • Gearbox services with negative pressure containment • Cavitation hole repair tenting.

• Infrared thermography identifies overheating electrical connections and provides significant warning of potential problems.

• Vibration trending and analysis can diagnose imbalance, misalignment and bearing issues on the spot.

• On-line motor testing is an advanced data collection service. It pinpoints the challenges that rotating machinery faces by separating mechanical and electrical issues.

• Metal stitching is a mechanical bonding process that can repair damaged sections of machinery on-site with little or no disassembly. In-house machining of large generator shaft.

Catastrophic damage to a housing Repaired housing after metal stitching EL CID Technician verifying the successful as seen prior to metal stitching. is complete. completion of restack and rewind via EL CID.

Our specialty services ensure that EL CID testing • Significant reduction in safety equipment is returned to like new EL CID testing is the modern way to hazards condition. test stator core insulation and safely • Instant analysis of stator core Metal stitching detect insulation breakdown condition between core laminations. Metal stitching is a unique and highly • Detects deep seated faults, developed mechanical bonding pro- With fully digital processing, digital even under windings cess that is used to repair broken EL CID produces results that have an and damaged castings. improved clarity, especially CO2 dry ice cleaning noticeable when the results have • Repaired areas are restored to been acquired in a noisy CO2 dry ice cleaning is an efficient original strength environment. and cost-effective way to minimize downtime while achieving superior • Many times, repairs can be made El CID is also used as part of our cleaning results on-site without the need for major rigorous quality program. It can be disassembly used to test the quality of a repair • Non-abrasive, non-flammable and or a re-wedging, prove quality on a non-conductive • Since no heat is used, this cold new machine or provide evidence • Environmentally friendly and repair process causes no distortion of satisfactory repair. or change in properties of the contains no secondary parent metals Benefits of EL CID testing include: contaminants

• Relieves locked-in stress and • Rapid setup CO2 dry ice cleaning is being used eliminates high stress area by successfully in many applications redistribution • Can be done with coils in place including electrical power and rotating equipment (electric motors, • Low power supply requirements windings, hydroelectric generators, (1-3 kVA) and bearings).

CO2 technician using hand held nozzle Generator as seen prior to CO2 cleaning. Generator as seen after on-site to perform on-site generator cleaning. CO2 cleaning is complete.

©2016 Schulz Group, a brand of Timken Gears & Services Inc. All rights reserved. Repair capabilities include low and medium Custom control panel as designed Each overhauled gearbox undergoes voltage breakers and protective relays. by the custom controls team. an instrumented, full-speed test.

Switchgear testing and repair Whether replacing individual com- Gearing solutions from ponents, updating wiring and pro- a world leader Switchgear and transformers are gram documentation, or redesigning essential elements in power supply an entire control system, Schulz The Schulz Group now offers gear- systems. Schulz Group provides a Group will work with you to evaluate box repair services, and is the only range of low and medium voltage your present system’s condition and New England-based supplier to have services including switchgear provide upgrade options that apply. access to the SOP’s and intellectual maintenance, inspection and testing. property of Philadelphia Gear, Western State-of-the-art variable speed Gear, WesTech and DeLaval Steam Maintenance programs prevent drives, coupled with modern process Turbine brand gear drives. catastrophic failures and unexpected feedback transmitters and program- downtime. Allowing Schulz Group mable controls, can allow existing As part of a network of regional service to design a complete maintenance production equipment to operate centers focused on total power train program for you, including predictive with more flexibility, increase pro- solutions, Schulz Group is uniquely testing and preventive maintenance, duction with less waste and lead positioned to offer its customers’ we will work together to develop to more uptime and better quality. inspection, overhaul and upgrade a site-specific maintenance plan solutions for their mission critical gear that includes condition monitoring In short, better control means drives. We use the same processes, at specified intervals. better reliability. procedures that Philadelphia Gear has pioneered since 1892, and we Controls back it all with a best-in-industry 3-year warranty. Designing and installing energy saving systems is a core focus of our custom controls and systems integration team. Many existing systems are poorly documented and hard to troubleshoot and fix. Besides being prone to breakdown, many systems suffer from a lack of replacement part availability and manufacturer support.

Technician performing final testing of breaker prior to delivery and installation.

Custom Control Systems Motors and Generators Specialty Services

• Energy efficiency upgrades • Motor and generator repairs • Metal stitching for crack repairs in-house to 9000HP/40 ton • Full system engineering • EL CID testing • Vacuum pressure impregnation • PLC design and programming (VPI) systems • CO2 dry ice cleaning

• System integration of motors, • Full voltage testing to 13,800V • Low and medium voltage controls and pumps AC; 1200V DC switchgear testing and repair

• Gearbox services Testing Services • Turnkey services and maintenance programs • Predictive maintenance and • On-line motor testing • Electrical services including stator diagnostic services rewinds, core iron restacks, including • EL CID testing • In-place hydro turbine overhaul uprates and coiled redesigns • Core loss testing • Mechanical repairs to runners, Machine Shop Services • On-site services such as dynamic gates, and bearings balancing, and laser alignment • Large machining capabilities

• Infrared thermography New Product Sales • Babbitt bearing repairs

• Vibration trending and analysis • Motors • Vertical and horizontal digital boring mills • Variable frequency drives (VFDs) • Dynamic balancing to • Gearboxes 60,000 lbs. • Pumps • Welding – TIG, MIG, Arc and Gas • Controls • Flame spray metalizing • Parts and accessories

The Timken team applies their know-how to improve the reliability and performance of machinery in diverse www.schulzelectric.com markets worldwide. The company designs, makes and markets high-performance mechanical components, including bearings, gears, belts, chain and related mechanical power transmission products and services.