Presentation on theme: "TurboCare Sp. z o.o. TECHNICAL OVERVIEW"— Presentation transcript:
1 TurboCare Sp. z o.o. TECHNICAL OVERVIEW April, 2007
2 TurboCare sp. z o.o. – structure SIEMENS AGWIBREM Sp. z o.o80% shares20% sharesPRUFTECHNIK WIBREMTurboCare Sp. z o.oTurboCare 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.
6 TurboCare sp. z o.o. activities: Field installation serviceSteam & gas turbines overhaulFact finding of turbine conditionNDT (incl. Replica & microscopy analysis)Machining services: on-site and in workshopRepair and retrofit of turbine componentsBlades replacementRotors straighteningVibration measurement and rotors balancingLaser alignment serviceOil service
7 TurboCare sp. z o.o. turbine overhaul workshop 19982300 m2Overhead crane 50 tTool storeSocial and office areaElectrical supply system 1,2 MWHeating system 800 kWRoads for heavy transport2006
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 fact finding Machine diagnose beforee overhaul Measurement of alignmentClearances measurementNon destructive testingDestructive material testingMaterial testing with replicaOil purity testingPhoto documentationVideo endoscopyFact finding protocolMachine diagnose after overhaul
25 vibration diagnostic Vibration measurement Vibration analyze Balancing at siteAnalyze of blades vibration
26 Grit blasting with cooper slag sand, aluminum oxide and glass pearls
27 non-destructive testing Flaw detection and metallographic tests:Vibration measurementVibration analyzeCracks 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 non-destructive testing Work in high temperature with high stresses is the source of cracks of turbine parts.
29 endoscope test 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
31 After overhaul turbine casings are ready for assembly. turbine casings overhaulAfter overhaul turbine casings are ready for assembly.
32 turbine casings material structure rectify 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.Crystal grain before and after normalization of turbine casing material.
33 turbine rotors straightening Run-out before straightening – to 5,40 mmRun out after straightening – max 0,12 mm
38 Mobile boring machine WK-1 mobile machinesMobile boring machine WK-1Bore diameter – to 2600 mmRadial feed – to 200 mmAxial feed – to 200 mmMax. Length of inner part of casing – 4600 mmMachining the bore of IP 200 MW turbine casing
39 Mobile boring machine WK-2 mobile machinesMobile boring machine WK-2Bore diameter – from 1300 to 4000 mmBearings distance – 5030 mmWeight – kg
40 LP casing of 200 MW turbine machining at site mobile machinesLP casing of 200 MW turbine machining at site
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 mobile machines Diffusers boring machine WD -1 Bore diameter 50 – 1000 mmDepth of machining to 1300 mmMachining of the cylindrical and axial surfaces