We are a consortium of engineers serving the Power Generation industry providing broad-ranging consulting services. Our combined experience exceeds 160 years in power-plant maintenance, welding & joining, and material science.

Randy Corn

President, Senior Consulting Engineer

Power Consulting Solutions, Inc.

34 Years Experience as an Executive Outage Engineering Leader, Manufacturing Leader in Gas Turbines , Operations, and certified welder

• 26 Years with General Electric’s Power Division
• Manager, Outage Engineering
• Gas Turbine, Steam Turbine, Generator, Oil & Gas, & Wind Speciality Tooling Development
• Six-Sigma Black-Belt Certified
• 12+ years as certified welder in all positions, using x-ray on super alloys & all common alloyed materials
• Stanford D-School, Institute of Design Graduate
• Awarded 8 Innovation and 15 Engineering awards for outage productivity at GE
• Graduate of GE Manager Development Course, Crotonville, NY
• Foothills Welding Technology – Associates (Graduated top in class)
• BSBA Southern Wesleyan University, Mechanical Engineering Greenville Technical College
• Enjoy the Challenges of Repairing All Things Mechanical

Leader & consultant with extensive experience in Gas Turbine onsite processes including GE compressor & HGP upgrades, specializing in maintenance operation improvements that reduce outage cost.  Significant knowledge in Steam Turbine (including Nuclear), Generators, Oil & Gas equipment, and Wind Turbine outage productivity. Extensive knowledge in specialty tooling design, development, and industrialization on Gas Turbines, Steam Turbines, Generators, and Wind Turbines. Emphasis on Gas Turbine outage optimization including cycle, cost, quality, and safe work practices. Significant experience leading large engineering and hourly manufacturing/service teams to execute various functions both at customer sites and manufacturing facilities globally.

Key attributes:

• 18 issued patents (US & International)
• Pre-Product Research & Development
• Multi-Generational Technology & Product Planning
• Services Productivity & Customer Relationship Management
• FMEA & RCA Risk Mitigation
• Led Large Engineering & Services Teams
• Industrial Facilities & Lab Construction
• Formerly a Certified Welder by 100% X-Ray in All-Positions on Super
• Super alloys and all other common materials
• Welding & Fabrication of Super Alloys
• Multi-Site & Global Operations Management
• Led Large Engineering and Services Teams
• New Product Development & Industrialization
• Engineering & Manufacturing Processes
• Talent Acquisition & Development
• Organization Gap Analysis & Team Start-Up
• ST Open, Clean, Close & General Inspections
• Graduate of Stanford’s Executive Design School

Paul Turley

Owner, Senior Consulting Engineer

Turley Consulting, LLC

• Manager Turbine Generator repairs. Charlotte, Nc
• Manager Mechanical repairs Charlotte, Nc
• Manager Turbine repairs. Atlanta, Ga
• Manager Steam-Gas turbine rotor repairs. Houston, Tx
• Valve & Stationary steam turbine component repair leader
• Nuclear steam turbine repair leader
• Rotating steam turbine repair leader

Paul has over 39 years of experience in the repairs of turbines, generators and balance of plant equipment for all major OEM designs. Paul started his career as field machinist working on steam turbines for QPI (GE subsidiary). Paul then moved to General Electric repair shop as a machinist. Afterwards he spent  two years on the GE technical repair leadership program. Later Paul accepted the role of  Manager Turbine Generator Repairs in the GE Charlotte shop and subsequently at the GE Atlanta shop. Paul took a role with Preco Turbine Services in Houston as a Repair Manager for Gas and Steam turbines supporting all OEMs. GE purchased Preco Services reunited Paul with the GE family. Soon after he took a position as The Productivity Leader developing steam turbine repair methods.

• Repair Solutions – finding methods of repair for the one time or emergent repairs
• Machining  –  expert in all types including turning, milling, CNC, rotor dovetail & body machining, shell, valves and stationary components
• Steam turbine Bucket/Blade replacement and general repairs
• Low speed balance
• Diaphragm/stationary blade manufacturing and repairs
• Developed the use of portable coordinate measure machine ”CMM” to perform inspections of turbine components.
• Developed stationary component repairs. Adapted the component manufacturing weld methods to the stationary turbine component repair methods.
• Project manager Fukushima nuclear rotor outage. 8 rows of buckets and 8 diaphragm change out
• Project manager Catawba Nuclear – Removal of 1200 buckets/blades and machine repair dovetails, Machine buckets/blades and reinstall within 40 day outage
• Winyah Station conversion. Converted inlet nozzle design from 90 degree to 180 degree arc which consist of welding the inner casing with 1100 Lbs. of filler wire. All welding was performed using hand held sub-arc method.
• Project manager shell weld repair BBE Zierbena, Spain. Weld repair and machining of the outage shell.
• Developed the pre-machining of bucket covers/shrouds. Machine conical covers/shrouds before attaching to rotor to reduce final machining

Key attributes:

• Automotive technical training 1979
• Diaphragm /stationary repair 1985
• Bucket / blade repair 1986
• Rotor low speed balance 1990
• GE Technical leadership program 1990-1992
• Advanced Bucket repairs 1991
• Generator field rewind 1992
• Generator Stator rewind 1992
• Piedmont community College Drafting 1991

Larry Grycko

Owner, Senior Consulting Engineer

Welding & Technical Services, Inc.

25 Years with General Electric Co. in Power Services & Gas Turbine Manufacturing

Extensive experience in Nuclear and Fossil Power Plant construction and maintenance planning, repair drawing preparation (fluent in AutoSketch), welding research and development, welder training, welder performance qualification and production supervision, procedure development and writing, cost estimating, scheduling and man loading, including turbine rotor’s, pipe and valves and structural steel, manual and remote-semi-automatic GTAW, SAW, SMAW, MIG/FCAW and other processes. Familiar with ASME BPVC Sec IX, Welding and Brazing Qualifications, AWS D1.1 Structural Steel Welding Code, D1.3 Sheet Steel Welding Code and D3.6 Underwater Welding Code. Very familiar with operating, programming, and troubleshooting AMET GTAW/SAW systems as well as Arc Machines Inc GTAW remote welding systems. Expert in extreme narrow groove weld prep and equipment design.

Key attributes:

• Quoted, planned and supervised all rotor welding for GE.
• Supervised the repair of 159 turbine & generator rotor welds: (35 wheel buildups, 172 forgings attached, 114 seals, 11 stub shafts, 11 thrust faces, 12 heat lathes)

• Led the rotor repair welding facility move Chicago to Schenectady
• Under my leadership the rework free rotor welding run continues to 90+ rotors and 10 years.
• Created and maintain welder qualification certifications for GE Power Services business.
• Led the development and execution of the first ever L0 FineLine forging repair (7.5” deep extreme narrow grove), on budget and schedule with excellent results.
• Prepared the purchase specification, planned and supervised the installation and operation of the new custom-built turbine rotor weld station with 200 ton by 40ft capacity.
• Planned and supervised 24” long through wall (5” thick) crack repair of HP upper inner shell. Machine and grind double bevel full pen weld prep, weld, NDE, PWHT, final machine, NDE.
• Improved a 20-30% rotor welding rework problem in early 2000’s timeframe

Carter Cook

President, Senior Consulting Engineer

CSC Northeast

Over 25 years of experience in management, development, supervision, and training in the welding industry

Extensive experience in the development and execution of robotic, manual, and remote-semi-automatic welding processes and repairs. Familiar with ASME BPVC Sec IX, Welding, and Brazing Qualifications, AWS D1.1 Structural Steel Welding Code, D1.3 Sheet Steel Welding Code, and D3.6 Underwater Welding Code. Expert at rapidly developing and executing repairs for steam turbines, gas turbines and generators within outage constraints.

Key attributes:

• 7 issued patents
• Numerous awards, recognition, and publications
• Developed and supervised the first robotic T-G rotor weld repair
• Supervised the largest generator rotor weld repair
• Supervised over 100 casting repairs on-site
• Developed numerous robotic weld repairs for valves, diaphragms, turbine blades and casings
• Established Welding School For High School Students Capital District BOCES
• CWE Certified Welding Educator
• CWI Certified Welding Inspector
• NDE Level II Certification
• ASME Certified in the following welding processes SMAW, GTAW, FCAW, SAW, PAW, OFW, BZ, GMAW-R, GTAW-R
• BSME SUNY Polytechnic Institute
• AS Automotive Technology SUNY Canton
• AS Welding Hobart Welding Institute