Power GenerationRebuild & Manufacturing
Steam turbine rebuild, gas turbine rebuild, rotating equipment rebuild, and component manufacturing for critical equipment.
Power Generation
Rotating Equipment Rebuild for Critical Components
Power generation teams rely on HFW for rotating equipment rebuilds, including the steam turbine repair and gas turbine repair applications detailed in our technical articles, as well as turbine component rebuilds and new part manufacturing. These workflows may include hardfacing, thermal spray coatings, precision grinding services, inspection, and documentation.
HFW is trusted as a Tier 1 supplier in power generation and can handle medium and large jobs that many shops cannot.
For reliability engineers, HFW helps address wear, delamination, runout, coating failure, and repeat maintenance. For planning teams, HFW brings coating, machining, grinding, and inspection into one schedule. For procurement, HFW provides one accountable supplier for capital projects and rebuild programs where precision, reliability, and quality are demanded.
From its Buffalo, New York facility, HFW serves national and international power generation customers with one-source manufacturing and rebuild support.
Applications
Power Generation Components HFW Supports
Turbine Shafts & Rotors
Turbine shafts and rotors rebuilt or manufactured for power generation service, with coating, grinding, inspection, and documentation built into the workflow.
Steam Turbine Valve Components
Valve discs, seats, stems, and hardfaced surfaces where Stellite® delamination, fusion quality, and inspection discipline affect reliability.
Piston Rods
Piston rods manufactured or refurbished for power generation service, with machining, coating selection, and finish precision grinding planned around the application.
Turbine Blades & Wear Surfaces
HVOF tungsten carbide wear coatings on turbine blades, including complex components with small wear surfaces that require careful masking and finishing.
Seal & Bearing Fits
Dimensional restoration, coated running surfaces, cylindrical grinding, and final inspection for journals, seal areas, and bearing areas.
Large Precision Work
Medium and large power generation jobs, including shafts up to 10 feet long, where precision, reliability, and quality documentation are required.
Turbine Rebuild
One-Source Services for Turbomachinery
Steam Turbine Repair
Repair and manufacturing for steam turbine valves, rotors, shafts, journals, blades, and buckets using hardfacing, HVOF coatings, machining, precision grinding, and inspection.
Gas Turbine Repair
Repair and manufacturing for gas turbine rotors, shafts, journals, blades, housings, and fit-critical parts using HVOF coatings, machining, precision grinding, EMRO inspection, and TIR checks.
Case Study
Steam Turbine Valve Rebuild and Stellite® Delamination
A large southeastern utility contacted HFW after experiencing Stellite® delamination on valve discs and seats made from chromium-molybdenum steel, with valve stems made from an iron-base superalloy. The objective was straightforward: eliminate delamination and restore confidence in service life expectations.
HFW engineered the full workflow around reliability, including welding controls, cooling controls, and inspection. The rebuild prevented repeat delamination for at least five years, giving the utility confidence that the process solved the failure mode rather than simply replacing the overlay.
Controls Used on the Project
- •Proper preheat and strict interpass temperature control
- •Controlled weld procedure to manage dilution and improve fusion
- •Controlled post-weld cooling treatment
- •Liquid penetrant and ultrasonic inspection by an AWS-certified inspector
- •All work completed in one facility under one quality system
One-Source Workflow
Rebuild and Manufacturing with Coating, Grinding, and Inspection
Power generation jobs often cross process boundaries. HFW coordinates the full workflow inside one ISO 9001:2015 facility.
Manufacture New
HFW can manufacture new shafts, rods, valve components, and other power generation parts from customer-supplied or HFW-furnished material.
Rebuild & Remanufacture
Worn or damaged components evaluated for rebuild, remanufacturing, or replacement, with coating and grinding planned around the right outcome.
HVOF & Thermal Spray
HVOF and thermal spray processes apply wear, heat, and corrosion-resistant coating systems, including carbides, cobalt alloys, and ceramic powders.
Hardfacing & Weld Overlay
Stellite® 6, cobalt-based alloys, nickel-based alloys, and controlled weld procedures support valve and severe-service component reliability.
Grinding & EMRO
Precision grinding brings coated and rebuilt surfaces to final geometry. EMRO inspection supports monitored rotating equipment.
Quality Documentation
ISO 9001:2015 quality, documented travelers, calibrated gauges, CMM support, LP/UT inspection where required, and final QC signoff.
HFW at Work
Power Generation Manufacturing and Rebuilding
Related Reading
Power Generation Resources
FAQ
Power Generation Rebuild Questions
Does HFW provide rotating equipment rebuild for power generation?+
Yes. HFW supports power generation rotating equipment rebuild, including turbine shafts, rotors, piston rods, seal areas, bearing journals, and valve components.
Can HFW provide steam turbine rebuild services?+
HFW supports steam turbine rebuild services through machining, hardfacing, thermal spray coatings, precision grinding, inspection, and rebuild planning for critical components.
Can HFW rebuild Stellite delamination on steam turbine valve components?+
Yes. HFW can evaluate Stellite® delamination and rebuild valve surfaces using controlled preheat, interpass temperature control, post-weld cooling, and LP/UT inspection when required.
Does HFW provide gas turbine rotor rebuild?+
HFW supports gas turbine rotor rebuild and related turbomachinery rebuild with coating, grinding, machining, EMRO inspection, and final QC documentation.
Does HFW support gas turbine maintenance and turbine parts rebuild service?+
Yes. HFW supports gas turbine maintenance programs and turbine parts rebuild service through machining, HVOF coating, precision grinding, hardfacing, inspection, and documentation for critical components.
Can HFW support teams comparing gas turbine rebuild providers?+
Yes. HFW supports utilities, OEMs, and repair organizations that need coating, machining, precision grinding, EMRO inspection, and documentation from one ISO 9001:2015 facility.
Can HFW manufacture new turbine shafts or piston rods?+
Yes. HFW manufactures new turbine shafts, piston rods, and related components from customer-supplied or HFW-furnished material.
Need a Power Generation Component Quoted?
Send HFW your drawings, photos, failure mode, coating requirements, inspection criteria, and outage timeline. We will help define the right rebuild or manufacturing workflow.
Attribution Statements
- Stellite® is a registered trademark of KENNAMETAL INC.