Customer: Nextra Energy – Point Beach Nuclear
Project: Expansion Bellows Replacement – Unit 1 Condenser
Location: Two Rivers, Wisconsin, USA
Completion Date: April 2019
Asset Type
Nuclear Power – Turbine Condenser
Project Scope
Field Machining & Expansion Bellows Removal/Replacement
Environment
Confined Space, Elevated Temperature, Active Welding Nearby
Bellows Sizes
12", 16", 24", 36"
Quantity
8 bellows in each of 3 condensers
Special Requirements
Minimal Foreign Material Entry (FME), low-profile cutting equipment, strict clearance limitations
Schedule Impact
Contributed to outage reduction from 32 to 28 days
Nextra Energy approached Hydratight with a critical machining task during a time-sensitive Unit 1 outage at Point Beach Nuclear. Three condensers required removal of eight expansion bellows each - components essential for managing thermal expansion under the turbine. The bellows were positioned vertically at the very top of the condenser, extremely close to the turbine casing and to each other. Clearances were tight: some cuts were within 3 inches of the turbine and 6 inches apart. Complication added to complexity
Confined space environment
with limited access for equipment and personnel
Requirement for minimal FME
(Foreign Material Entry) - due to vertical orientation above the condenser
Simultaneous welding operations
creating heat exposure and air-quality concerns
Need for lightweight equipment
capable of precision cuts without extensive rigging
Hydratight’s engineering team conducted a full review of condenser prints, bellows design, and access constraints. The solution combined:
1. Purpose-built, low-profile machining equipment
We deployed a range of Mirage DL Ricci NB clamshell cutters, selected specifically for their lightweight design, rigidity, and extremely low profile. This allowed crews to manoeuvre safely in the confined turbine deck area without sacrificing cutting accuracy.
2. Custom tooling for zero-compromise FME control
Because all cuts were vertical, Hydratight designed specialised tooling that prevented foreign material entry while still enabling smooth cutting and beveling operations.
3. Field machining trailer pre-stocked for continuity
To protect the outage timeline, we mobilised:
- Fully equipped machining trailer
- Spare equipment and cutting tools
- Additional personnel trained for confined-space machining
This ensured no unplanned delays from equipment swaps or tool shortages.
4. Coordinated multi-discipline safety management
Hydratight worked closely with Nextra Energy craft labor to manage:
- Heat stress risk
- Ventilation and air monitoring
- Limited personnel density in the condenser
Safety and productivity were maintained throughout the project.
Hydratight’s precision planning and onsite execution directly contributed to Nextra Energy successfully reducing the overall outage schedule from 32 days to 28 days - a significant achievement for a nuclear facility. Key outcomes included:
despite vertical machining and tight clearances
enabled by lightweight clamshell systems
supported by onsite spare equipment
ensuring reliable installation of new bellows
reinforced by delivering within challenging spatial and thermal constraints
Hydratight provides specialised field machining solutions engineered for the most constrained, sensitive, and high-risk environments.
If you need precision, safety, and zero compromise on schedule, we’re ready to help.
Contact Hydratight to discuss your project.
