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April, 2007 TurboCare Sp. z o.o. TECHNICAL OVERVIEW.

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Presentation on theme: "April, 2007 TurboCare Sp. z o.o. TECHNICAL OVERVIEW."— Presentation transcript:

1 April, 2007 TurboCare Sp. z o.o. TECHNICAL OVERVIEW

2 Privileged & Confidential – Page 2 TurboCare sp. z o.o. – structure SIEMENS AG WIBREM Sp. z o.o WIBREM Sp. z o.o TurboCare Sp. z o.o 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.

3 Privileged & Confidential – Page 3 TurboCare sp. z o.o. - employment

4 Privileged & Confidential – Page 4 TurboCare Spa SerWestca Masaood John Brown MJB International TurboCare Ltd Thailand TurboCare Gas Turbine Services TurboCare Pty Ltd Turbine Services Limited TurboCare Inc TC Poland TurboCare International TurboCare – locations map TurboCare Sericos em Turbomaquinas Ltd Kadon Electro Mechanical Service Ltd

5 Privileged & Confidential – Page 5 TurboCare companies TurboCare IncTurboCare International, GmbH

6 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

7 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

8 Privileged & Confidential – Page 8 inside of workshop

9 Privileged & Confidential – Page 9 LP rotor – 36t ready for sandblasting

10 Privileged & Confidential – Page 10 machines in workshop – 1 Heavy horizontal boring machine – to 65 t. Horizontal boring machine

11 Privileged & Confidential – Page 11 machines in workshop – 2 Heavy latheL = 8 m D = 2850 mm Load – 30 t LP rotor of 120 MW turbine machining

12 Privileged & Confidential – Page 12 machines in workshop – 3 Horizontal lathe D = 3500 mm, Load = 65 t Heavy boring machine

13 Privileged & Confidential – Page 13 turbines in workshop Field for turbine assembly

14 Privileged & Confidential – Page 14 work in situ at power plant BBC 300 MW turbine

15 Privileged & Confidential – Page 15 work in situ TurboCare uses own containers for site preparation. Container city in Power Plant

16 Privileged & Confidential – Page 16 work in situ Tool storage near turbine Mobile lathe and mobile mill near turbine.

17 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

18 Privileged & Confidential – Page 18 TurboCare installed in 2002 for Alstom – 3 skids with gas compressors system in Poland. instalation

19 Privileged & Confidential – Page 19 Major overhaul of 200 MW turbo – generator of LMZ design steam turbine overhaul

20 Privileged & Confidential – Page 20 gas turbine overhaul VANTA PP – Finland Gas turbine 80 MW

21 Privileged & Confidential – Page 21 Diaphragm blade assembling Compressor & turbine New blades of turbine rotor

22 Privileged & Confidential – Page 22 hydro turbine overhaul

23 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.

24 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

25 Privileged & Confidential – Page 25 vibration diagnostic Vibration measurement Vibration analyze Balancing at site Analyze of blades vibration

26 Privileged & Confidential – Page 26 Grit blasting with cooper slag sand, aluminum oxide and glass pearls grit blasting

27 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;

28 Privileged & Confidential – Page 28 Work in high temperature with high stresses is the source of cracks of turbine parts. non-destructive testing

29 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

30 Privileged & Confidential – Page 30 Cleaning, NDT, cracks removing; Welding repair; Dimensions control; Machining; Bolts replacement; Assembling. turbine casings overhaul

31 Privileged & Confidential – Page 31 After overhaul turbine casings are ready for assembly. turbine casings overhaul

32 Privileged & Confidential – Page 32 After 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.

33 Privileged & Confidential – Page 33 turbine rotors straightening Run-out before straightening – to 5,40 mm Run out after straightening – max 0,12 mm

34 Privileged & Confidential – Page 34 turbine rotors straightening

35 Privileged & Confidential – Page 35 Blades assembly blades replacement

36 Privileged & Confidential – Page 36 TurboCare assemblies all kind of turbine blades. blades replacement

37 Privileged & Confidential – Page 37 Siemens design blades assembly blades replacement

38 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

39 Privileged & Confidential – Page 39 Mobile boring machine WK-2 Bore diameter – from 1300 to 4000 mm Bearings distance – 5030 mm Weight – kg mobile machines

40 Privileged & Confidential – Page 40 LP casing of 200 MW turbine machining at site mobile machines

41 Privileged & Confidential – Page 41 Mobile boring machine for turbine casings The biggest in the world D = 6000 mm, L = mm TurboCare Sp. z o.o. design and manufacturing

42 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

43 Privileged & Confidential – Page 43 mobile machines

44 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

45 Privileged & Confidential – Page 45 Milling machine for surface and grooves machining mobile machines

46 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

47 Privileged & Confidential – Page 47 Drilling machine with swivel head. mobile machines

48 Privileged & Confidential – Page 48 mobile machines

49 Privileged & Confidential – Page 49 laser alignment of turbines

50 Privileged & Confidential – Page 50 AEG turbine modernization

51 Privileged & Confidential – Page 51 Oil filtering and flusing mobile system oil purity control and flushing

52 Privileged & Confidential – Page 52 Low speed balancing at site with mobile machine High speed balancing with Schenck machine in Brno turbine rotors balancing

53 Privileged & Confidential – Page 53 turbine overhaul in workshop

54 Privileged & Confidential – Page 54 turbine overhaul in workshop

55 Privileged & Confidential – Page 55 turbine overhaul in workshop Preliminary assembling in TurboCare workshop

56 Thank you for your attention WROCLAW – CITY OF TurboCare Sp. z o.o. LOCATION


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