• MAIN PLANT: 150,000 FT2

• 250 SKILLED EMPLOYEES• 2 PERMANENT SHIFTS• SERVICE 24/7, 365 DAYS • 22 OVERHEAD CRANES• MAX CRANE CAPACITY: 65 TONS• FIELD & OUTAGE SUPPORT

Chalmers & Kubeck, Inc.

ISO 9001:2008 & 10CFR50 Appendix B / NQA-1 2008/09NR Certificate of Authorization (Stamp # 105)

Established 1950INDEPENDENTLY Owned

• CNC MANUFACTURING• GEAR SERVICES• ROTATING EQUIPMENT &

FIELD MACHINING • WELDING & FABRICATION• ENGINEERED PUMPS• THERMAL SPRAY & GRINDING • VALVE SALES & SERVICE

Prominent Member of the AGMAPrecision Gear Manufacturing up to 2M Diameter (74”)

Spur, Helical, and Double Helical Gears

GEAR SERVICES

Internal Form Grinding Spur & Helical

Gear Sets

Probe Checking Gear Tooth Geometry

Gearbox RepairGear Tooth Contact Pattern

Planetary Gear Box Re-Build

CustomGear Drives:

Reverse Engineered, Upgraded, Fabricated, Machined & Assembled

Tube Reduction

Saddle

Reverse Engineered, Upgraded

Components, Fabricated, Machined

& Assembled

Custom Gear Drive HousingReverse Engineered, Upgraded Design, Built &

Tested

Table Drive and Shear Drive Re-Build

Pickle Line Re-CoilerComplete Package Overhaul

Safety Related Gear Drives High Pressure

Coolant Injection Charging Pump Cooling Tower Traveling Screen

Circulation Water Traveling Screen

• Repair / Replace Screen Baskets• Linkages, Pins, and Composite

Bushings• Head Shaft, Sprockets, and Tensioners• New S.S. Piping w/ Hydro Test

Gear Field Services: Repair, Machining & Maintenance

Removal & Installation Complete Overhauls Laser Alignments Bore Scope Inspections Vibration Analysis Technical Assistance

Field Machining Services• Bearing Journal Sleeve Repair

• 24” max dia.• Boring / Turning

• 50” max dia.

• Drilling / Tapping • Studs up to 5” dia.

• Facing • 50” dia. (in house) / 120” dia. (rental)

• Heat Exchanger Repair• Resurfacing of Tube Sheet /Shell • & Division Plates

• Milling• Machine Base Milling 48” x 120”• Keyway Relocating, Enlarging & Repair

• Turn-Key Services• Vibration Analysis, Equipment Removal & Repair, Equipment Installation, Alignment, Balancing

• Valve Repairs• Hard Face Removal, Weld Build-up & Seat Angle Machining

Air Powered CLIMAX MODULATHE Boring / Facing

Machine

24” Capacity SILK ID Mount Flange Facing Machine

2” Hydraulically Powered Line Bore Machine – Pump

Casing

DL-RICCI 8” OD Mounted Journal Lathe

4’ DL-RICCI Milling Machine

OD Mount Clam-Shell Pipe Cut & Weld Prep Machine

Capability up to 16” diameter

Gas Turbine Burner Repair

Weld, NDE & Machining

Turbine Blade Assembly & Tip Grinding

Diaphragm: Wet Magnetic Particle Inspection, Re-vane,

and Assembly

Turbine Overhauls

- Elliott- Terry

- Murray

Turbine Shaft

Chrome Oxide (Plasma) Carbon Seal Area Tungsten Carbide, 17% Cobalt (HVOF) Bearing Journal

SCHENCK Balancing up to 5,000 lbs.

Fabrication & CNC Machining

Double Decker Hydrogen Collector Blower

Faro Edge CMM Arm with Laser Scanner

Dimensional Verification & Replication

Faro Ion Laser Tracker

Setup, Dimensional

Verification, and Layout

Accuracy.0004” In-Line @ 8m

.0009” Horizontal Scale Bar @ 2m.00019 Horizontal Scale Bar @ 10m

Cable Drum - Precision Ball Milling

Fly Cutting w/ Right Angle Head – Horizontal Mill

Small Fabrications and Custom Manufacturing Solutions

Air Bearing

Blade Ring

5” Scale

Welding Certifications National Board NR Certificate of Authorization National Board Repair (R Stamp) ASME Section IX Certified Welders ASME U and PP Stamp Certified ASME B31.1 and 31.3

Turbine Stop Valve Seat

Finish Machining

Stellite Hard Facing

Large Vessel Fabrication & Welding

STRONGBACK Fabrication & Machining

Nuclear Waste Storage Cask

Fabrication & Machining(41 Tons – Crane Capacity 65 T)

Large CNC Horizontal Milling Max 30’ Long & 14.5’ High

Large CNC Vertical Turning

Max 32’ Diameter & 10.5’ High

Condensate Pump Motor

Stand Machining

Gray VBM: Twin HeadTable – 14’

Height – 12’ 9” (Under Tool)

Large Shaft RefurbishmentUp to 30’ Long w/ 91.5” Swing Over Ways

Engineered Pumps

High Speed Barrel Style PumpRunning Clearances, Straightness & Fits Restored to O.E.M.

Specifications

Pump Casing Line Bore

Pump Case RestorationBrazing, Inserts, and Machining

Goulds Pump Naval Bronze Restoration

Bearing & Case Ring Fits Worn / Pitted

Thermal Spray Repair, Split Face Machined, and Line Bored

Thermal Spray Repair Using Aluminum Bronze

Circulating Water Impeller Restoration

Pump Discharge Head Reverse Engineering, Fabrication, Machining &

Assembly

Circulating Pump Overhaul

Circulating Pump – 84” Worthington Hi-Flow

Service Water Pump

Heater Drain Pump

Barrel Style High Speed Feed Pump

Complete Turn Key Field Service

5 Relief Valve Test StationsSteam – 1,500 psi ● Air – 3,000 psi ● Hydrostatic – 10,000 psi

• Valve Plant: 27,000 ft2

• Service 24/7, 365• Field & Outage Support• 9 East Coast Service Centers

Chalmers & Kubeck, Inc.ISO 9001:2008 & 10CFR50 Appendix B / NQA-1 2008/09

NR Certificate of Authorization (Stamp # 105)

Largest East Coast Consolidated (G.E.) PSV Commercial Stocking Distributor – BOP Only

Stamps: “VR”, “NR-VR”, “V”, & “UV”

Hydrostatic Testing

Line Valve or Mechanical Equipment

Max 20,000

psi

Limitorque Blue Ribbon Facility

Factory Authorized Service CenterLargest East Coast Limitorque Master Distributor

Expert BOP Sales, Service, and Field Support

Thermal Spray 101

• What is Thermal Spray• What is it Used For• Typical Industrial

Applications• Coating Deposition

Methods• Process & Coating

Characteristics

Thermal Spray 101What is Thermal Spray?

Thermal Spray 101

Surface RestorationService Induced WearManufacturing Errors

Protective CoatingFretting and/or WearGallingErosionCorrosionOxidation / Hot Corrosion

What is it Used For?

Example of Thermal Spray Reclamation / Dimensional Restoration

Thermal Spray 101 Babbitt Bearings Bronze & Iron Casting Repair Hard Chrome Alternative Hydraulic Rams and Pistons Pipe Elbow I.D.s Roll Resurfacing Rotating Equipment

Shafts, Shaft Sleeves & Coupling I.D. Bearing Journals & Seal Diameters Housing & Stuffing Box Bores Case & Wear Rings Blowers, Fans, Impellers & Turbines

Strainers Valves

Gates & Balls Seats, Stems, and Trim Sets Spring Aluminizing

HVOF Tungsten Carbide Coating of a Piston Rod

Typical Industrial Applications

Thermal Spray 101Deposition Methods

Flame Spray Babbitt and low temp anti-

corrosion Electric Arc Spray

Predominately Metal Coatings

High Velocity Oxygen Fuel (HVOF) Premier method for Carbide

application Atmospheric Plasma

Spray (APS) Premier method for

Ceramic application

Kinetic Energy (Left to Right)Thermal Energy (Bottom to Top)

Thermal Spray 101Deposition Method: Electric Arc Wire Spray

Electric Energy Wire Feed Stock

Predominantly Metallic Coatings

Cored Wires allow Advanced Material Compositions

Most Economical Surface Restoration Process Versatile and Simple High Deposition Rates Machine Finish

Readily Portable

Thermal Spray 101Deposition Method: High Velocity Oxygen Fuel (HVOF)

A high pressure combustion “flame” heats and propels the powder particles. Extremely high particle velocities: 3,300-3,900 FPS – Supersonic! (JP-5000/8000) Very dense coatings – porosity <1% Highest Bond strengths of Carbide and M-CrAlY type coatings Tests exceed the strength of the epoxy (> 10,000 PSI) F-35

X-45

Thermal Spray 101Deposition Method: Atmospheric Plasma Spray

Powder Feedstock Plasma energy produced

from high intensity arc + plasma forming gases: Ar, He, H, N, or combinations

Highest thermal energy of all the thermal spray processes (~17,000 ○F) and is the optimal method for application of ceramics & ceramic-metal cermets.

Most versatile deposition process and well suited to spraying I.Ds.

Thermal Spray 101 Application process is line-of-

sight. Spraying of Internal diameters is possible using a special I.D. gun or by using an angled spray technique (limited).

Unlike a fusion weld, the method of sprayed particle adhesion is generally mechanical; surface preparation is critical. Dissimilar materials can be

joined – a HP coating can be placed on an inexpensive base material!

The minimal heat input does not distort the base material like welding!

While the coatings do not add mechanical strength, they are generally more wear resistant than the same material in wrought or cast form. With a HP coating, it’s possible to increase functional service life up to 3x!

Coatings must be sealed for the intended application.

General Process & Coating Characteristics

Hydraulic Ram Refurbishment

• Thermal Spray Repair – Electric Arc Spray w/ 400 series Stainless Steel

• Finish Grinding

Pump Shaft SleevesDimensional Restoration & Protective Coatings

Left: Large Sleeve:

New, Monel w/ Cr2O3-SiO2TiO2

Small Sleeve: Nitronic-50, w/ Bond Coat, Hard Stainless Overlay, and Tungsten Carbide Protective Coating.

Right: Large Chrome

Oxide Sleeves Installed

C&K, the “OEM Alternative” Nuclear Cost Avoidance Case Studies

Worthington 2-Stage Heater Drain Pump

PROBLEM: Between 1990 and 2005, there were 9 seal failures requiring rebuild and 2 bearing failures due to water intrusion from seal failures.

SOLUTION: Engineering developed a mod package in conjunction with C&K to upgrade the intermediate bushing to a non-galling composite that would stabilize shaft dynamics. C&K provided on-site supervision during the pump / seal assembly.

RESULTS: Since the implementation of these changes, there have been NO SEAL FAILURES on the associated pump resulting in an approximate cost avoidance of > $97,000. Seal Rebuild Kits: $7K Planning & Maintenance

costs per seal rebuild: $15K.

Above costs do not include OPS, RP, Work MGT, etc.

PROBLEM: Service Water Stuffing Box Sleeve - Wear

Equipment: Four Vertical Turbine PumpsJohnston on Unit 1 & Fairbanks-Morse on Unit 2

Problem: Premature wear on stainless steel stuffing box shaft sleeves.Leaks and excessive maintenance.Max service life only 11 – 13 months before sleeves

required replacement!

Cause: River silt coupled with obsolete pump packing effectively ground away the relatively soft sleeves.

SOLUTION: Service Water Stuffing Box Sleeve - Upgrade

Solution: New shaft sleeves manufactured by

C&K and coated w/ Plasma application of Chromium Oxide

Softer Garlock packing material

Results: Shaft Sleeve hardness increased

from ~28Rc to ~70Rc The Utility Engineer classified this as

a success story within 2 months due to significantly reduced maintenance.

Customer inspection after one year revealed no sleeve degradation whatsoever. Pump returned to service with simple packing change-out.

Upgraded Shaft Sleeves with Chrome Oxide Coating

Circulating Water Strainer - Cone

Significant wear and erosion around tapered O-Ring groove area – 316L S.S.

O-Ring groove area restored and then upgraded with HVOF Tungsten Carbide coating for particle wear resistance – 64 Rc

Circulating Water Strainer- Body

Wear groove from strainer cone sealing gasket (0.160”) – 316L S.S.

Tapered seal area restored using Alloy 400 (Monel) for marine corrosion resistance.

Service Water Strainer - Shaft

Strainer shaft packing area worn (0.180” deep) – “obsolete” flame spray coating

Strainer shaft packing area restored and upgraded with a plasma applied chromium oxide ceramic (69-75 Rc)

20” Service Water Strainer - Cone

C&K restored the O-Ring groove using Aluminum Bronze Thermal Spray in 3 Weeks at a fraction of the OEM replacement cost

Service Water Strainer – BodyField Repair & Machining – Cast Bronze

Problem: Strainer Body > $300,000 to

purchase new Removal / re- installation

~$350,000 Welding not possible

Solution: Strainer Body

Thermal Spray repaired at customers’ site with Aluminum Bronze using C&K machine tool designed and built for this application.

Circulating Pump Bearings & ShaftPROBLEM

Problem: Premature bearing wear, shaft wear, and greater than desirable vibration levels.Cutlass Rubber Bearing required

replacement after 1.5 - 2 yearsWorn bearing would result in increased

pump vibrationPump Shaft Journals were being worn

away by abrasive media

Cause: Cutlass Rubber bearing material trapped sand/silt and effectively ground away the pump shaft.

Circulating Pump Bearings & ShaftSOLUTION

Solution:Pump shaft journals coated by C&K

w/ Plasma applied Chromium Oxide Ceramic

Green Tweed AR1 composite bearing installed w/ reduced running clearances

Results: Lowest vibration level of the

customer’s mixed flow vertical pumps!Bearing & Shaft service life increased

3x after the upgrade with anticipated 4x (9 years overhaul target) – that’s a huge ROI

Cutlass Rubber Bearing

Green Tweed AR-1 Bearing

Pump Shaft SleevesDimensional Restoration & Protective Coatings

Left:

Large Sleeve (New): Monel w/ Chromium Oxide Ceramic Coating

Small Sleeve (Repaired): Nitronic-50, w/ Bond Coat, Hard Stainless Overlay, and Tungsten Carbide Coating

Right:

Large Chrome Oxide Sleeves Installed

Customer Involvement

CASE WEAR RINGS – upgraded from Nitronics 60 to Greene Tweed composite

IMPELLER WEAR RINGS, STUFFING BOX & SHAFT SLEEVE – restored dimensions and upgraded w/ Chromium Oxide

FEMALE COLUMN FITS, IMPELLER BOWLS & BORES – restored using hard stainless thermal spray

LINE COUPLINGS – thermal sprayed IDs with hard stainless as anti-galling to aid in subsequent disassembly

3-Stage Service Water PumpOVERHAUL

Feedwater Pump Breakdown Bushing & ShaftPROBLEM

Equipment: WGID Pump, 375 ◦F Treated Water

Problem: Common failure upon start-up - the 410 S.S. pump shaft would contact the 410 S.S. breakdown bushing (labyrinth design) resulting in galling and pump seizure.

Cause: Temperature stratification during start-up would distort pump case in relation to shaft resulting in the loss of the original running clearances; the pump would seize.

Feed Water Pump Breakdown Bushing & Shaft SOLUTION

Solution: Pump sleeve coated by C&K w/ Plasma application of Chromium

Oxide (Cr2O3-SiO2-TiO2) opposite bushing area Green Tweed WR525 thermoplastic composite bushing with non-

labyrinth design installed with reduce running clearances.

Results: Upgraded breakdown bushing with protective chromium oxide

coating on pump sleeve achieved same pressure reduction of original labyrinth seal without galling / seizing or shaft damage. The upgraded configuration functions almost like another bearing!

Upgraded design has been functioning for over 6 years with expected 7.5 – 9 years before service required.

Station Air Heat Exchangers

Problem: MIC damage to 316 S.S. tube sheet faces.

Solution: Wetted face area repaired and upgraded with a Hastalloy C thermal spray coating at a small fraction of the replacement cost.