Turbine & Generator Field Service Engineer

Donald Callahan

*** ** *****

Pattonville, Texas 75468

850-***-**** (cell)

Work Experience

Contractor - Alstom, Incorporated

March 17, 2010 - June 4, 2010

Supervisor: Paul Nagel 804-***-****, Rolf Schmidt 804-***-****, James Hall 804-***-****

Position Held: Technical Field Advisor and day shift Outage Manager for Basin Electric Power - Laramie II, Wheatland, WY.

Scope of work: HP-IP and front standard inspections. Installation and upgrade of nozzle plates, #2 and #3 diaphragms.

Contractor - Alstom, Incorporated

February 1, 2010 - March 15, 2010

Supervisor: Paul Nagel 804-***-****, Rolf Schmidt 804-***-****, James Hall 804-***-****

Position Held: Technical Field Advisor. Developed a generator procedure for upcoming outage at Fayetteville, Texas.

Outage planning for Basin Electric Power - Laramie II, Wheatland, WY. GE 550 MW unit.

Contractor - Alstom, Incorporated

September 7, 2009 - December 15, 2009

Supervisor: Paul Nagel 804-***-****, Rolf Schmidt 804-***-****, James Hall 804-***-****

Worked from my home

Position Held: Technical Field Advisor developing turbine schedules utilizing Project 2. GE schedules developed: Combination intercept and reheat stop valve schedule, 4 each control valve schedule, 2 each main steam stop valve schedule (1 with bypass and 1 without), front standard schedule, generator schedule, HP-IP schedule, LP schedule, main steam stop valve hydraulic servos schedule, intercept and reheat stop valve hydraulic servos schedule, HP-IP, LPA, LPB, generator schedule in series/parallel.

Contractor - Alstom, Incorporated

May 29, 2009 - May 31, 2009

Supervisor: Paul Nagel 804-***-****, Rolf Schmidt 804-***-****, James Hall 804-***-****

Position Held: Technical Field Advisor. Attend pre-outage meeting with Dale Williams for J. H. Miller, Jr. Steam Plant - Alabama Power Company. Scope of work for upcoming outage season turbine/generator and valve maintenance units 3 and 4 for major outage work.

Contractor - Alstom, Incorporated

May 21, 2009 - May 28, 2009

Supervisor: Paul Nagel 804-***-****, Rolf Schmidt 804-***-****, James Hall 804-***-****

Position Held: Technical Field Advisor for installation of T/E and G/E LP L-0 blades.

Burred out and inspected 38 steeple cracks on T/E LP L-0 rotor. Burred out and inspected 26 steeple cracks on G/E LP L-0 rotor.

Contractor - Alstom, Incorporated

May 14, 2009 - May 17, 2009

Supervisor: Paul Nagel 804-***-****, Rolf Schmidt 804-***-****, James Hall 804-***-****

Position Held: Technical Field Advisor for inspection of Alstom retrofit turbine thrust bearing (disassemble and reassemble).

Contractor - Alstom, Incorporated

February 21, 2009 - May 3, 2009

Supervisor: Paul Nagel 804-***-****, Rolf Schmidt 804-***-****, James Hall 804-***-****

Position Held: Technical Field Advisor for inspection HP-IP and LP turbine inspection. Inspection of 4 each control valve and servos, 2 each stop valves and servos, 2 each reheat intercept valves and servos, 2 each reheat stop valves and servos, 2 each boiler feed pump steam turbines and valves inspection. Installation of 2 each Alstom LP rotors and stationary components at Widows Creek, Tennessee Valley Authority.

Contractor - Power Equipment Maintenance

October 26, 2008 – December 18, 2008

Vice President of Field Operations Supervisor: Scott Cavendish: 864-***-****

Position Held: Manager for installation of 140 new generators at the Fowler Ridge Wind Farm, Fowler, Indiana

Managed 20 mechanics and one supervisor during the removal and installation of 140 new generators on Vestas wind turbines. Managed cost, safety, schedule and monitored productivity. Reported daily on progress of work to Mr. Cavendish and Glenn Marlow, Manager of Field Operations for Vestas.

Contractor – Alstom, Incorporated

September 17, 2008 – October 17, 2008

Supervisor: Paul Nagel 804-***-****, Rolf Schmidt 804-***-****

Position Held: In-house technical review of upcoming outages in Richmond, VA.

100MW unit owned by ALCOA

1100 MW unit owned by Tennessee Valley Authority

Reviewed cost, schedule, scope of work, safety plan and quality plan for two upcoming outages.

Contractor – Alstom, Incorporated

March, 2008 – June, 2008

Supervisor: Bob Scott 804-***-****

Position Held: Dayshift G.E. Technical Field Advisor

Outage for Tennessee Valley Authority in Evansville, KY (Paradise Plant). Turbine inspection consisting of HP, LPA, LPB, install new generator field, four CV’s, two SV’s, one combination intercept and reheat stock valve, all hydraulic servos, one BFP steam turbine, valves, servos and all lube oil pumps.

Florida Power & Light, Juno Beach, Florida (retired 2008)

May 21, 1979 - January 1, 2008

Supervisor: Tom Broad 561-***-****

Positions Held: Outage Manager, Outage Supervisor, Foreman, Mechanical Apprentice Instructor, Certified Welder Itinerate, Mechanic Itinerate

Outage Manager Accountabilities:

Note: The following outages are examples of work performed in this position. I have provided oversight on 15 outages while in this position.

Outage Manager Port Everglades (30 day outage) unit 3 & 4. (2) Foster Wheeler boilers and (2) GE 400 MW units. Summary of large jobs:

Replaced (2) circulating water pumps

Replaced all traveling screens

(2) generator re-wedge

(2) right hand stop valve rebuild

(2) combination intercept and re-heat stop valve rebuild

(4) FD Fan hydraulic coupling rebuild

Boiler work, clean, inspect, duct work, air pre-heater basket replacement, tuber samples, re-heater tube repairs.

Zero injuries. Jobs finished on time, on budget.

$7,000,000 budget.

Outage Manager Martin County (80 day outage) Unit 4 (2) General Electric 7-FA Gas Turbines and D-11 steam turbine. Summary of large jobs.

7-FA gas turbines, (2) rotors sent off to have compressor section unbolted and replaced. All stationary compressor blades were replaced on both units. Hot gas path and combustor outage on both units.

D-11 steam turbine inspection, diaphragms dished .050 to .175 Dishing removed by stress relieving and machining. T-1 and T-2 bearings and journals repaired and machined to bring within spec.

(2)boilers and aux equipment inspected and repairs made.

$30,000,000 budget.

Outage Manager High Winds Site in California (14 day outage). New installation of (68) Vesta wind turbines

Evaluated sites maintenance processes on safety, inventory of parts, maintenance of mechanical, electrical and instrument and controls. Also, evaluated sites criteria for acceptance of new units after construction. Made recommendations and implemented updated processes.

Outage Manager Cabazon and WPP93 Wind Site in Palm Springs, California (60 day outage). Return 90 Zon 750 wind turbines to service.

Troubleshoot all downed units to determine failed components. Assessed parts needed to return all units to operation. Scheduled contractors to perform work and return units to service.

Outage Supervisor (South Region) Accountabilities:

Accountabilities included 4 of FPL’s power plant facilities (outage work).

Port Everglades Power Plant, (2) 400 MW units and 2 175 MW units.

Fort Lauderdale Power Plant, (2) combine cycle units (2 on 1) 800 MW

Cutler Power Plant, (1) 150 MW unit and 1ea 75 MW unit

Turkey Point Fossil, (2) 400 MW units

Oversaw 4 foreman and 32 mechanics.

Addressed personnel issues as they arose. 75% of all foremen in Florida came from the south region.

Interviewed and hired 100 + mechanics in the last 4 years of my career. Provided supervision during their probationary period of employment prior to them moving to other regions.

Developed 90% of all FPL’s General Electric G-2 turb/gen/valve/servo procedures. Developed numerous Westinghouse procedures for 175 and 800MW turbines/gen/valves/servos. Developed quality checks and hold points with OEM’s spec’s and service allowable clearances.

Accountable for zero outage injuries, cost, durations, manpower, contractor services, trucking and site surveillance on parts at vendors shops.

Worked with OEM (GE Dallas) service shop to enhance the procedures on their D-11 turbine valves. GE valve engineers implemented all suggestions.

Provided management in California on High Wind Site, Palm Spring Wind Site, Cabazon Site and WPP93 Site. Experience on Vesta and Zon 750 units. Removed and replaced hubs, blades, generators, gearboxes, nacelle, pitch drives, yaw drives. I was the contractor supervisor over “run energy” to complete work at the Cabazon and WPP93 Wind sites.

Performed site surveillance on turbine components at GE service shops, Westinghouse service shops, Elliott’s, Liddy’s, PME, Southern Grinding machine shops.

Outage cost ranged from a $2,000 to $10,000,000. Accountable for all pre-outage and post -outage issues.

Foremen Accountabilities:

Accountable for a 17 man/women crew, while developing safety behaviors, skills, productivity, attendance and maintaining positive work attitudes. Addressed personnel issues as they arose.

Maintain 2 Foster Wheeler Boilers, 2 GE 400 MW turbines and all the necessary auxiliary equipment to support them.

Maintain spare parts to support short notice outage work, unscheduled outages and unit trips.

Schedule shifts and crew size to support outages.

Develop and improve plant procedures.

Possess expertise on General Electric’s G-2 steam turb/gen/valves/servos. I have been the back shift TFA/Supervisor during numerous outages.

Apprentice instructor for all fossil and nuclear power plant mechanical apprentices. Hands on instructional classes were held after normal working hours. This was a four year program. During Turkey Point and Saint Lucy Nuclear power plant outages I taught Mechanical Apprentice 10 hours per day 6 days per week to keep employees on schedule.

Selected as one of the instructors (1985) to develop and teach a Leadership Training Program (performance management) to all foremen in FPL’s system. This was a 5 day program taught in Orlando. This training class was given a second time (2001) to all foremen in FPL. I worked as one of the instructors. I gave this training to all plant managers and engineers that had personnel reporting to them.

Mechanic Itinerate Accountabilities:

Drug tested every 6 months

Ability to align rotating equipment boiler feed pumps, condensate pumps, forced draft fans, hydraulic couplings, steam turbines and generators. Installation of mechanical seals, rebuild horizontal split casing centrifugal pump (heater drain pump) vertical pumps (condensate pump) positive displacement pump (fuel oil burner pump). Replace rotating element in Byron Jackson Feed pumps, rebuild gauge glass, pipe fitting, layouts, blue print reading, rigging, and using precision instruments.

Operate mobile crane’s and turbine deck gantry cranes.

Rebuild mechanically operated valves, globe, gate, wedge gate, diaphragm, Hi-drop, check, economizer inlet valve.

Welding, certified in schedule 20, 40, 60, 80 and 160 tubing/piping carbon steel, stainless steel and inconel. Buddy welding boiler tubes (one welder inside and one welder outside of the boiler). Certified in tig-welding root pass using consumable inserts (electric boat, Navy term) on heavy wall main steam inlet lines. Welded on numerous boiler outages, replacing v-bottoms, front, rear and side water wall boiler tubes. Mirror welded radiant roof tubes. Welded tube leaks in all sections of boilers.

Dissembled and re-assembled a wide range of steam and combined cycle turbines, GE and Westinghouse. They ranged from 75 to 800 Mega Watts.

Rebuilt turbine valves/servos on all FPL GE and Westinghouse turbines.

Rebuilt a wide range of IKs.

Florida Keys Aqueduct Authorities, Florida City, Florida

September 1973 – April 1979

Supervisor: Art Williams

Position Held: Diesel Engine and Pump Foreman/Mechanic

Maintain (6) White Superior Diesels and (6) Fairbank Morris Diesels at Cross Key, Tavernier Key, Long Key, Marathon Key and Ram Rod Key pumping stations. Diesels engine’s were operated on a 24/7 schedule.

Maintain/rebuild (14) 12 inch inlet by 12 inch outlet pumps and 12 speed increasers.

Other job responsibilities: Maintain adequate inventory of parts on hand, schedule and execute major overhauls, perform daily maintenance activities, rebuild cylinder heads, injectors, exhaust turbochargers, pumps, speed increasers, valves, Woodward Governors.

Trouble shooting abilities and parts availability were critical in eliminating down time during the non-outage season.

Attended Miami Dade Junior College and took 15 credit hours in chemistry, Algebra 1 & 2. Received a C License in Water Treatment in the State of Florida. Certification required for promotion.

Redland Construction Incorporated, The Redlands, Florida

June 1971 – September 1973

Supervisor: J. W. Payne

Positions Held: Maintenance Superintendent, Mechanic Foreman, Mechanic/Welder.

Maintenance Superintendent: Responsible for supervision of 3 mechanics and 2 welders.

Mechanic/Welder: Handled the day to day repairs needed to keep equipment operable.

Mechanic Foreman: Responsible for all equipment used while building the last 3.5 miles of Florida’s turnpike.

Trouble shoot, maintain, repair/rebuild the following equipment:

38B, 71B, 88B Bucyrus Erie Draglines.

12E, 14E Caterpillar and Huber Road Graders.

Caterpillar Road Pans (6 yard machines)

988, 950, 966 Caterpillar loaders.

R-30 and R-35 Euclid off the road rock hauling trucks.

Maintained Gardner Denver and Mayhew dynamite drilling rigs.

Made weld repairs to equipment, trailers and platforms.

References

Gregg Deittmer, Manager FPL, 561-***-****

Tom Broad, Director of Centralized Maintenance FPL, 561-***-****

Jamie Hickson, Outage Manager FPL, 863-***-****

Bob Scott. Alstom Power Inc.

John Wells, General Electric Manager

More references are available upon request.

List of professional training sessions attended is attached.

Training Log

Basic Trainings:

Certified Welder, sch 40, 80 160 and heavy wall piping

In plant clearance process for all power plant equipment (fossil and nuclear).

Respirator Use and Care (passed medical exam and fit test)

Confined Space for Power Plants

Asbestos Awareness, hands on training (Glove Bagging) on 16”, 12” and 6” piping.

Hazardous Waste Awareness, Communication, Right to Know Laws and MSDS Logs.

Oil Spill Response - hands on training at the US Navy site in Key West Florida. Operating a 20 ft. boat, deploying 100 feet of floating boom, oil absorbent towel removals.

Emergency action processes for hurricanes, fires, ammonia & chlorine releases and man-down drills.

Stairs, walkways, portable fire extinguishers, First Aide, CPR

Boilers, Turbines, Generators, Turbine Valves and Servos. 160 class room hours on each segment was necessary to complete each course. I received an average score of 96 or above on all classes.

Turbine steam path audits.

Todd Burners - trouble shooting, inspections and rebuilding.

Safety Behavior Based Training, Stop program, safety audits, conducted safety meetings and held training classes on specific safety related equipment.

Contractor Administration, Contractor Safety, Contractor Clearance Process.

Scaffold user and qualified builder.

Computer training

QIP, (Quality Improvement Process) Team Leader and member on numerous teams.

Leadership 101 - A & B

Leadership High Performer

Training Nuclear Power Plants:

FBI background check

Red badge trained for access to the RCA (radiation controlled area)

Welding - nuclear qualified on carbon steel, Tig. and Stick.

Qualified on tensioning and de-tensioning the reactor head.

Installation of RCP (reactor cooling pump) mechanical seals.

Qualified to dissemble and reassemble 750 MW Westinghouse steam turb/gen/valve.

Inspection and rebuilding RCA containment building snubber’s (hydraulic spring cans).

Picked as one of two mechanics to be trained on rebuilding steam generator reactor cooling water pump at Turkey Point Power Plant Unit 3.

Education

South Dade High School, Homestead FL 1970

Miami Dade Junior College, Miami FL 1974. Fifteen credit hours in Chemistry, Algebra I, Algebra II. Received a C License in Water Treatment (state of Florida).

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