28MW Steam Turbine Generator Rehabilitation

A major industrial power plant in Nigeria depends on two 14MW steam turbine generators as the backbone of its electricity supply. These turbines, originally commissioned decades ago, had provided years of reliable service powering critical industrial operations. As the plant's infrastructure aged, the performance and reliability of both turbine units began to deteriorate, signalling the need for a comprehensive intervention before minor degradation escalated into catastrophic failure.

Both 14MW steam turbine generators experienced significant mechanical degradation due to age, continuous high-load operation, and accumulated deferred maintenance. The breakdowns threatened to take the plant's entire 28MW generation capacity offline — with severe consequences for production continuity and operational revenue.

The plant required a full-scope overhaul, not a patch repair, that would restore both units to original operational capability. This demanded deep expertise in legacy steam turbine systems, access to specialised tooling, and the ability to execute a large-scale rehabilitation within the constraints of a live industrial environment where every hour of extended downtime carried substantial financial cost.

MIMAH mobilised a team of steam turbine specialists to conduct a comprehensive audit and rehabilitation programme. The work began with a detailed condition assessment of both turbine generator units, identifying degradation patterns, component wear, and critical areas of concern across rotors, casings, bearings, seals, blading, and auxiliary systems.

Following the audit, we executed a complete disassembly of both steam turbine generators. Every component underwent thorough cleaning, non-destructive examination (NDE), and precision measurement against original equipment manufacturer specifications. A comprehensive Disassembly, Cleaning, and Inspection (DCI) report was compiled and submitted, providing the plant with a definitive picture of each unit's condition and the precise scope of restoration required.

Procurement of replacement parts was managed through MIMAH's established supply chain, ensuring OEM-equivalent quality with reduced lead times. Throughout the process, MIMAH also scoped and proposed a long-term service agreement to ensure ongoing reliability and prevent the recurrence of accumulated degradation.

The complete DCI of both 14MW steam turbine generators has been successfully delivered, providing the plant with comprehensive engineering documentation and a clear roadmap for full restoration. The rehabilitation programme is ongoing, with MIMAH managing procurement, reassembly, and commissioning of both units.

Upon completion, the plant will recover its full 28MW generation capacity with significantly extended equipment lifespan. The proposed long-term maintenance programme will shift the plant from reactive to preventive maintenance, protecting the investment and reducing the risk of future unplanned outages.