april, 2007 turbocare sp. z o.o. technical overview
TRANSCRIPT
April, 2007
TurboCare Sp. z o.o.
TECHNICAL OVERVIEW
Privileged & Confidential – Page 2
TurboCare sp. z o.o. – structure
SIEMENS AGSIEMENS AG WIBREM Sp. z o.o
WIBREM Sp. z o.o
TurboCare Sp. z o.oTurboCare Sp. z o.o
PRUFTECHNIK WIBREM
PRUFTECHNIK WIBREM
80% shares
20% shares
TurboCare Group, with 17 businesses around the world and over 2,500 highly skilled employees covering industrial and power generation market in more than 100 countries, is the world's largest Independent Service Provider offering maintenance support to owners and operators of rotating equipment manufactured by major industry OEMs.
Privileged & Confidential – Page 3
TurboCare sp. z o.o. - employment
0
50
100
150
200
250
300
1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
Year
EMPLOYMENT
Privileged & Confidential – Page 4
TurboCare SpaTurboCare Spa
SerWestcaSerWestca
Masaood John BrownMasaood John Brown
MJB InternationalMJB International
TurbTurboCare LtdoCare Ltd ThailandThailand
TurboCare TurboCare Gas Turbine ServicesGas Turbine Services
TurboCare Pty LtdTurboCare Pty Ltd
Turbine Services Turbine Services LimitedLimited
TurboCareTurboCare Inc Inc
TTCC Pol Polandand
TurboCare InternationalTurboCare International
TurboCare – locations map
TurboCare Sericos em TurboCare Sericos em Turbomaquinas LtdTurbomaquinas Ltd
Kadon Electro Kadon Electro Mechanical Service LtdMechanical Service Ltd
Privileged & Confidential – Page 5
TurboCare companies
TurboCare Inc
TurboCare International, GmbH
Privileged & Confidential – Page 6
TurboCare sp. z o.o. activities:
Field installation service
► Steam & gas turbines overhaul
► Fact finding of turbine condition
► NDT (incl. Replica & microscopy analysis)
► Machining services: on-site and in workshop
► Repair and retrofit of turbine components
► Blades replacement
► Rotors straightening
► Vibration measurement and rotors balancing
► Laser alignment service
► Oil service
Privileged & Confidential – Page 7
TurboCare sp. z o.o. turbine overhaul workshop
► 2300 m2
► Overhead crane 50 t
► Tool store
► Social and office area
► Electrical supply system 1,2 MW
► Heating system 800 kW
► Roads for heavy transport
1998
2006
Privileged & Confidential – Page 8
inside of workshop
Privileged & Confidential – Page 9
LP rotor – 36t ready for sandblasting
Privileged & Confidential – Page 10
machines in workshop – 1
Heavy horizontalboring machine – to 65 t.
Horizontal boring machine
Privileged & Confidential – Page 11
machines in workshop – 2
Heavy lathe L = 8 m D = 2850 mm
Load – 30 t
LP rotor of 120 MW turbine machining
Privileged & Confidential – Page 12
machines in workshop – 3
Horizontal lathe D = 3500 mm, Load = 65 t
Heavy boring machine
Privileged & Confidential – Page 13
turbines in workshop
Field for turbine assembly
Privileged & Confidential – Page 14
work in situ at power plant
BBC 300 MW turbine
Privileged & Confidential – Page 15
work in situ
TurboCare uses own containers for site preparation.
Container city in Power Plant
Privileged & Confidential – Page 16
work in situ
Tool storage near turbine
Mobile lathe and mobile mill near turbine.
Privileged & Confidential – Page 17
installation
TurboCare is ready for:
► assembling of old or new turbines
on new foundation
► precision leveling of machine frames
► transport of heavy units to plants
Privileged & Confidential – Page 18
TurboCare installed in 2002 for Alstom – 3 skids with gas compressors system in Poland.
instalation
Privileged & Confidential – Page 19
Major overhaul of 200 MW turbo – generator of LMZ design
steam turbine overhaul
Privileged & Confidential – Page 20
gas turbine overhaul
VANTA PP – FinlandGas turbine 80 MW
Privileged & Confidential – Page 21
Diaphragm blade assembling
Compressor & turbine New blades of turbine rotor
Privileged & Confidential – Page 22
hydro turbine overhaul
Privileged & Confidential – Page 23
kaplan turbine overhaul
TurboCare is prepared for major and medium overhaul of hydro – turbines.
Kaplan turbine rotor is dismantled for cleaning, measurement, NDT and overhaul.
TurboCare can perform services of all types of hydro turbines.
Privileged & Confidential – Page 24
fact finding
► Machine diagnose beforee overhaul
► Measurement of alignment
► Clearances measurement
► Non destructive testing
► Destructive material testing
► Material testing with replica
► Oil purity testing
► Photo documentation
► Video endoscopy
► Fact finding protocol
► Machine diagnose after overhaul
Privileged & Confidential – Page 25
vibration diagnostic
►Vibration measurement
►Vibration analyze
►Balancing at site
►Analyze of blades vibration
Privileged & Confidential – Page 26
Grit blasting with cooper slag sand, aluminum oxide and
glass pearls
grit blasting
Privileged & Confidential – Page 27
non-destructive testing
Flaw detection and metallographic tests:
► Vibration measurement
► Vibration analyze
► Cracks test in turbine casings and rotors;
► Magnetic particle test in UV rays of turbine blades;
► Ultrasonic test of shafts, couplings, casing joint surfaces, bolts and bearings;
► Endoscope test of hard to reach spaces;
► Visual examination of pipeline interiors with micro TV system (length up to 11m);
► Flaw examination of rotor central bores;
► Metallographic replicas for assessment of technical degradation of materials
working in highest temperatures;
► Hardness measurement for assessment of material condition;
Privileged & Confidential – Page 28
Work in high temperature with high stresses is the
source of cracks of turbine parts.
non-destructive testing
Privileged & Confidential – Page 29
► OLIMPUS - F7mm, 1,5 m long (photo
► registration);
► SONY – F6mm, 3 m long with video registration
and dimensions measuring system;
► TV camera – F30mm, 11 m long
endoscope test
Privileged & Confidential – Page 30
►Cleaning, NDT,
cracks
removing;
►Welding repair;
►Dimensions control;
►Machining;
►Bolts replacement;
►Assembling.
turbine casings overhaul
Privileged & Confidential – Page 31
After overhaul turbine casings are ready for assembly.
turbine casings overhaul
Privileged & Confidential – Page 32
After 150 000 hours of work, high temperature and stresses destroyed material structure of turbine casing.
Heat treatment is the best way to rectify the material structure.
turbine casings material structure rectify
Crystal grain before and after normalization of turbine casing
material.
Privileged & Confidential – Page 33
turbine rotors straightening
Run-out before straightening – to 5,40 mm
Run out after straightening – max 0,12 mm
Privileged & Confidential – Page 34
turbine rotors straightening
Privileged & Confidential – Page 35
Blades assembly
blades replacement
Privileged & Confidential – Page 36
TurboCare assemblies all kind of turbine blades.
blades replacement
Privileged & Confidential – Page 37
Siemens design blades assembly
blades replacement
Privileged & Confidential – Page 38
mobile machines
Mobile boring machine WK-1
► Bore diameter – to 2600 mm
► Radial feed – to 200 mm
► Axial feed – to 200 mm
► Max. Length of inner part of
casing – 4600 mm
Machining the bore of IP 200 MW turbine casing
Privileged & Confidential – Page 39
Mobile boring machine WK-2
Bore diameter – from 1300 to 4000 mm
Bearings distance – 5030 mm
Weight – 17 000 kg
mobile machines
Privileged & Confidential – Page 40
LP casing of 200 MWturbine machining at site
mobile machines
Privileged & Confidential – Page 41
Mobile boring machine for turbine casings
The biggest in the worldD = 6000 mm, L = 10000 mm
TurboCare Sp. z o.o. design and manufacturing
Privileged & Confidential – Page 42
Diffusers boring machine WD -1
Bore diameter 50 – 1000 mm
Depth of machining to 1300 mm
Machining of the cylindrical and axial surfaces
mobile machines
Privileged & Confidential – Page 43
mobile machines
Privileged & Confidential – Page 44
Pipes external work.
Inlet of steam pipes, with piston rings type sealing, need external surface machining for bushes replacement.
After machining
mobile machines
Privileged & Confidential – Page 45
Milling machine for surface and grooves
machining
mobile machines
Privileged & Confidential – Page 46
Machine for couple bores turning
Overhaul of coupling needs machining of bolt holes with knife when bushes are installed.
mobile machines
Privileged & Confidential – Page 47
Drilling machine with swivel head.
mobile machines
Privileged & Confidential – Page 48
mobile machines
Privileged & Confidential – Page 49
laser alignment of turbines
Privileged & Confidential – Page 50
AEG turbine modernization
Privileged & Confidential – Page 51
Oil filtering and flusing mobile system
oil purity control and flushing
Privileged & Confidential – Page 52
Low speed balancing at site with mobile machine
High speed balancing with Schenck machine in Brno
turbine rotors balancing
Privileged & Confidential – Page 53
turbine overhaul in workshop
Privileged & Confidential – Page 54
turbine overhaul in workshop
Privileged & Confidential – Page 55
turbine overhaul in workshop
Preliminary assembling in TurboCare workshop
Thank you for your attention
WROCLAW – CITY OF TurboCare Sp. z o.o. LOCATION