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 Equipment Modification and Redesign
Component Upgrade and Improvement
Hardware Procurement and Installation Supervision
Installation Design
Increase flow, power and efficiency by modifying existing in-house equipment.
Make troublesome turbine components more durable, more efficient and at the lowest cost.
Install new or used equipment otherwise too big or too small for other companies to handle.
Convert simple-cycle to combined-cycle or cogeneration.
Instituto Costarricense de Electricidad John Brown Engineering CADAFE
Engineering Design Group Stewart and Stevenson General Electric
Hydro Quebec Florida Power Turbine Services Limited Ventech
Puerto Rico Water Resources Authority Newfoundland and Labrador Hydro
Taunton Municipal Light and Power
Kuwait Gas Turbine Power Station
The following partial list, generated from the Fern Engineering project files, represents examples of our engineering design, modification, and hardware procurement services.
50 MW GAS TURBINE-GENERATOR SETS.
Fern Engineering furnished all civil, mechanical, and electrical design services for the installation of five gensets in the Middle East.
In addition to the installation, the design included facilities for fuel storage and off-loading, a protective foam supply system, a water storage tank and forwarding system, and a transformer deluge system.
COMPRESSOR RETROFIT AND MODIFICATION.
Fern Engineering provided a low cost, high volume pressurized air source for a refining process.
Fern modified an existing axial compressor to accept a used steam turbine driver.
The modification included couplings and provisions to accomodate changed rotor thrust.
Speed and surge operating limits were defined.
Equipment was installed and has been operating since 1982.
Result: Purchase of expensive specialized process equipment was avoided.
Modifying a used axial compressor was quicker, more cost effective, and satisfied the process requirement.
TURBINE BLADE REDESIGN EVALUATION.
Fern Engineering acted as a third party consultant on behalf of a major petroleum company to oversee the failure analysis and redesign of a primary OEM's 2nd stage gas turbine blade.
The client's gas turbines suffered several unexplained blade failures causing expensive production losses.
Fern worked closely with the OEM to identify the problem and to establish a corrective action plan, which included a significant redesign of the blade.
Result: The units were returned to operation with minimal downtime and improved reliability, saving the client considerable expense and loss of production.
ENGINE TEST FACILITY.
Fern Engineering designed the mechanical, electrical, and control systems for a unique double-ended test cell.
The facility is used to conduct testing of new and overhauled GE LM2500 and LM6000 gas turbines and features a 50 MW double-ended generator with a test cell at each end.
Fern provided the design for the test cell drive train, structural base and enclosure, engine subbase, inlet and exhaust ducting and connections, turbine engine transporter, and LM6000 exhaust diffuser.
Procurement drawings and specifications were provided for the generator lubrication system and turbine-generator couplings and spindles.
Unique pneumatic and hydraulic systems were designed and employed for the turbine septum wall and inlet module access doors.
Fern also provided the design for the fuel and lube oil quick connect/disconnect systems, the electrical, control, and fire protection systems.
Result: The owner has a rapid turnaround, state-of-the-art facility and is able to measure power output and heat rate before releasing a turbine to service.
GE MS5001N IMPROVED EXHAUST SYSTEM.
Fern Engineering redesigned the exhaust system of a fully fired combined cycle system to reduce pressure losses in the draft system.
The redesign included turning vanes, expansion joints, insulation, and a bypass damper.
Fern oversaw the installation of the system and final confirmation testing.
Result: Improved power and heat rate.
HOT GAS PATH DEVELOPMENT TEST STAND.
Fern Engineering was selected by a major industrial gas turbine manufacturer to perform the design, analysis, and manufacturing drawings for a High Temperature Turbine Development Test Stand.
The test stand was designed to accommodate a variety of first and third stage nozzles and to simulate the maximum temperature and pressure conditions encountered under start up and shut down cycles.
Result: The test stand was constructed and used in the development and improvement of hot gas path hardware for one of today's most widely used heavy industrial turbines.
POWER TURBINE IMPROVEMENTS.
Fern Engineering has designed modification kits that eliminate the operating and power restrictions in CW Mod Pod power turbines.
In addition to a complete redesign of the power turbine casing, Fern provides modifications to six other turbine components.
Fern fabricates the components via source-approved vendors, arranges for packaging and shipment, and provides installation supervision.
Twelve Mod Pod units have been modified with these uprated components and another ten are presently being evaluated for uprate.
Result: Mod Pod owners are able to realize up to twenty-five percent increase in power output.
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