OEM repair. Extend what performs
Everllence PrimeServ’s full range of repair services, from overhauls and modifications to complex repairs, are available both on-site through our field service teams and off-site at our service workshops around the world. Through our repair services, you have access to the latest versions of spare parts and components as well as our parts services. Our workshops use cutting edge technologies – such as 3D measurement, laser welding, and remanufacture. And our laboratories offer comprehensive material testing and in-depth analyses, utilizing state-of-the-art test stands that allow us to perform post-repair test runs to validate the performance of your equipment.
When planning turbine or compressor overhauls, repairs, or modifications, transparency is crucial to understanding the requirements of a project and completing the work on time. Therefore, our consulting engineers and veteran field service experts conduct inspections and root cause analyses to define the exact scope of repair. And we will keep in close contact with you to ensure there is minimum disruption to your business operations and processes.
Everllence PrimeServ
Your partner for repairs – 24/7, worldwide
delivering end-to-end maintenance, overhauls, and upgrades
delivering end-to-end maintenance, overhauls, and upgrades
Return to full performance with Everllence PrimeServ
Everllence PrimeServ is the service provider for the entire Everllence portfolio as well as third-party turbomachinery offering the full spectrum of services, solutions, and technologies that gives you access to high availability, efficiency, and capacity:
- Scheduled maintenance and inspections
- Repairs
- On-site recovery
- Consultancy to maximize the cost efficiency of your repair process
- Evaluation of remaining component lifetime potential
- Testing facilities
- Accredited material testing laboratory
- Next-generation technologies for maintenance, repair, and analysis
Get the most out of downtime
Repairs and large turnarounds represent an ideal opportunity to optimize equipment. We can incorporate most upgrades into repair and overhaul projects – without impacting the overall time for repair. And of course in this case, the cost of optimizing machinery while repairs are carried out is much lower.
Some optimizations add to your competitive edge, such as improvements to efficiency and reliability; others extend the service life of your equipment. Benefit from our expertise and intimate understanding of your machinery:
- Comprehensive concept from a single source
- Tailored concept to the needs of your operations
- Leverage advanced technologies
- No additional downtime
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PrimeServ case studies
Precision engineering that keeps industry moving
Our customer, an 80 MW power plant turning waste into heat and carbon-efficient electricity, needed a contractor to urgently repair the massive start-up damage to their steam turbine. The scope of work included refurbishment of the steam turbine rotor, assembly of twelve rotor blades, and refurbishing five guide vane carriers, which involved manufacturing and assembling 34 guide vane stages.
Everllence PrimeServ completed the whole project in a record time of five months. This meant our repair team cut the time-to-repair normally required for damage of this magnitude by over 30 percent, earning them praise from the customer for their “commitment and high levels of professionalism”.
After an incident severely damaged the rotor blades and stator vanes of an axial compressor, Everllence PrimeServ’s workshop in Zurich, Switzerland was tasked with the repair. The challenge was to shorten lead time as much as possible as the rotor and stator were already operating at reduced capacity due to a previous emergency repair.
To add to the complexity of the repair, cracks were found in two blade grooves of the shaft during dismantling. Our engineers repaired the stator and installed both new and refurbished vanes. The rotor was also fitted with new and refurbished blades. And two blade rows were redesigned with modified root profiles to match the re-machined shaft grooves.
Following the discovery of a significant intercooler leakage and erosion damage along the blade edges and impeller disc, the customer immediately classified the situation as an operational emergency. In response, MAN PrimeServ in Oberhausen, Germany prioritized the axial compressor repair to quickly restore performance and minimize disruption.
A detailed stress analysis was immediately conducted using the Finite Element Method (FEM), revealing that the existing blade contour was no longer safe for continued operation. To address this, our team developed a re-engineered blade profile, supported by a custom CAD design and 3D-printed grinding template. Precision grinding was then carried out, followed by non-destructive testing (NDT) to ensure structural integrity. Final verification confirmed that the restored blade matched the CAD contour and was ready for high-speed balancing (HSB) and reuse.
After a fire on-site, an axial compressor suffered major damage including broken rotor blades and deformed plastic on the guide blades. Unfortunately, no spare rotor was available. So, MAN PrimeServ were asked to carry out an emergency repair of the rotor and a temporary emergency repair of the guide blade carrier.
To restore the compressor to full functionality as quickly as possible, MAN PrimeServ engineers machined the existing rotating blades and ground the bearing points to ensure proper fit and alignment. Our workshop team renewed all sealing strips, conducted frequency measurements and performed high-speed balancing (HSB). Additionally, we manufactured a new stage 2 guide ring and carried out a complete repair of the guide blade carrier to stabilize the compressor’s operation.
As part of a complete overhaul, MAN PrimeServ inspected and repaired a chlorine compressor in their Berlin workshop. The scope of work covered:
- Inspecting and repairing the main and spare rotors
- Renewing and retrofitting the inner compressor parts
- Repairing and pressure testing the compressor casing
- Retrofitting the compressor monitoring
- Retrofitting the radial tilting pad bearings
- Retrofitting the bearing temperature and monitoring shaft vibration
- Workshop assembly of compressor
In support of ammonia production operations, our team undertook a comprehensive repair and overhaul project on a radial carbon dioxide compressor equipped with a manual washing system. The BBC (Brown, Boveri & Cie) machine was serviced both on-site and at our Ravensburg workshop in Germany.
The scope of work delivered by Everllence PrimeServ included:
- Complete overhaul of compressor stages 1 – 4
- Extensive refurbishment of the multi-stage gear box, with a 75% replacement of the gear set
- Installation of new BBC couplings to enhance torque transmission and operational safety
- Retrofit of the Inlet Guide Vanes (IGV) to improve flow control and energy efficiency
- Final installation and commissioning, delivering a fully restored and performance-optimized system
PrimeServ SolutionAdvisor – your goals, our service
Contact Everllence PrimeServ’s experts
Minimize time to repair, maximize availability
Everllence PrimeServ provides repair services whenever and wherever you need them. Our goals are to keep your equipment operational, shutdowns short, and maintenance costs low. For your operational certainty, we also keep expert teams on standby – to ensure you have quick and expert assistance in case of an unscheduled shutdown. Get in touch with us today.
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