Onsite Head Stud Removal and Recovery
Client: Major Power Generation Supplier – UK
Industry: Power Generation
Location: United Kingdom – Onshore Facility
Duration: Completed in Hours
Service: Onsite Head Stud Removal and Recovery
Overview
Royce Onsite Machining, a leading UK power generation maintenance provider, was engaged to perform urgent in-situ head stud removal on a critical turbine rotor. The seized head stud posed a risk of failure, potentially causing extended turbine downtime and costly component replacement.
Using Royce Onsite’s advanced head stud extraction technology, the team successfully removed and recovered the damaged head stud without the need to dissassemble the engine. The repair was completed in hours, allowing the turbine to return to full operational performance quickly and avoiding prolonged operational downtime.
Work Carried Out
Damage Assessment
- Inspected the seized head stud to assess surface damage, wear, and surrounding material integrity.
- Verified that the turbine components could safely undergo in-situ extraction without additional risk.
Head Stud Removal and Recovery
- Applied precision in-situ head stud extraction, a technique designed to safely remove seized studs.
- Recovered the original stud where possible, or replaced it with a precision-engineered OEM-compliant stud.
- Ensured adjacent components remained undamaged throughout the process.
Verification and Finishing
- Conducted non-destructive testing (NDT) to confirm the stud’s integrity and correct alignment.
- Checked torque and operational compliance in line with OEM specifications.
Technical Highlights
- Repair Method: Onsite head stud removal and recovery
- Technology Used: Precision in-situ head stud extraction
- Stud Recovery: Original stud successfully recovered or replaced with OEM-compliant component
- Downtime Avoided: Completed in hours, minimising operational disruption
- Verification: Non-destructive testing confirmed alignment and integrity
- Compliance: Fully in line with OEM standards
