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Welcome to GE Wuhan Boiler Company Ltd.
CHEN Chaoming GE Proprietary Information—Class III (Confidential) Export Controlled—U.S. Government approval is required prior to export from the U.S., re-export from a third country, or release to a foreign national wherever located.
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Emergency Evacuation – Office Building
Last edit: 00/00/2009 Emergency Evacuation – Office Building We are here
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访客安全须知 Safety Guidance for Shop Tour
Last edit: 00/00/2009 访客安全须知 Safety Guidance for Shop Tour 在您参观工厂过程中必须由WBC人员全程陪同。 The shop tour shall be accompanied by WBC personnel. 在生产现场,必须穿安全鞋和戴安全眼镜。 Always wear safety shoes and safety glasses. 在车间内请严格遵守安全警示标志和公司要求,严禁随意跨越警示线。 Obey all cautions and instructions, and never cross the warning line. 在车间内请沿绿色通道行走,并经由侧面的人员通道门出入厂房。 Walk along the green gangway, and always use the side personnel exit instead of the vehicle doors. 禁止随意触摸设备的旋转部分或高温物体的表面。 Never touch hot product or rotating equipment. 严禁在吊物下自由行走或停留。 Never stand or walk under any suspended loads. 为了避免眼部伤害,请不要直视电焊弧光。 Never stare at the welding work to avoid radiation burns to your eyes. 仅在指定区域使用手机且不超过3分钟。 Use mobile phone only in designated area no more than 3 minutes. 厂区内禁止拍摄及录影。 Photography and/or video are not allowed. 除吸烟点及办公楼指定区域外,公司内部禁止吸烟。 Smoking is prohibited except the smoking points and designated area in the Office Building. 垃圾应分类放入指定垃圾桶内。 Wastes should be disposed in designated containers.
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Agenda 通用电气锅炉业务简介 Profile of GE SPS Boiler 通用电气武汉锅炉股份有限公司简介 Profile of GE Wuhan Boiler Company Ltd. 通用电气武锅先进的技术 GE Wuhan Boiler Advanced Technology 通用电气武锅先进的管理 GE Wuhan Boiler Advanced Management
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通用电气锅炉业务简介 Profile of GE SPS Boiler
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蒸汽发电系统 Steam Power System Auxiliaries 辅机 Boilers 锅炉 Power Plants 电厂
last edit: Last edit: 00/00/2009 蒸汽发电系统 Steam Power System Auxiliaries 辅机 Boilers 锅炉 Power Plants 电厂 ECS 环境控制系统 Steam Turbines 蒸汽轮机 No 1 Steam Component Supplier 排名第一的蒸汽部件供应商 Generators 发电机 CCS 二氧化碳捕捉与储存 6
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India/Delhi, Shahabad, Durgapur
last edit: GE Boiler Germany/Stuttgart (EVT) USA/ Windsor (CE) India/Delhi, Shahabad, Durgapur China/ Wuhan (WBC) Singapore 符号 锅炉总部(新加坡) Boiler Headquarter 业务中心 Execution Center 新建项目制造基地 Manufacturing base for new build projects 研发基地 Research Center
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WBC CE ABL EVT BOILER “FAMILY TREE” last edit:
Alstom Boiler Deutschland GmbH (EVT) Power Inc. (CombuAlstomstion Engineering) Alstom India Ltd. Wuhan Boiler Company Ltd. Stuttgart, Germany Windsor, CT, USA New Delhi, India Wuhan China Alstom Power Inc. 2012 ALSTOM India Limited 2011 ALSTOM Boiler Deutschland GmbH 2000 2007 Alstom Wuhan Boiler Company Ltd. 2002 ALSTOM Projects India Ltd ABB-ALSTOM Power Wuhan Boiler Company Limited. Alstom Power Systems GmbH 1999 1997 2007 2000 ALSTOM Power India Limited ABB Power System Wuhan Boiler Group Co., Ltd. 2000 ALSTOM Power Boiler GmbH 1990 1995 ABB ALSTOM POWER INDIA LIMITED 1999 Combustion Engineering Wuhan Boiler Factory 1999 ABB ALSTOM Power 1953 1954 ASEA BROWN BOVERI MANAGEMENT LIMITED 1992 Combustion Engineering-Superheater Inc 1998 ALSTOM Energy Systems GmbH WBC 1948 Boiler/Mill facility established in Shahabad 1963 1989 GEC ALSTHOM 1912 Combustion Engineering (CE) Power Boilers facility established in Durgapur 1959 1970 EVT Energie-und Verfahrenstechnik GmbH CE ABL KSG Kohlenscheidungs-Gesellschaft GmbH 1921 EVT
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通用电气武锅简介 Profile of GE Wuhan Boiler Company Ltd.
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Preparation for establish-ment of Wuguo
Introduction to GE WBC WBC has more than 60 years of experience in designing and making boilers. 2015 2009 Joined GE Power 2007 Relocated to current site 1998 ALSTOM WBC Co., Ltd. Wuhan Boiler Group 1958 1953 Wuhan Boiler Works Preparation for establish-ment of Wuguo Gross land area: 463,000 m2 Covered area: 173,000m2 Employees: ~ Annul Capacity: 4500 MW. Current shares: Non-tradable ACL 51% and Wuhan Boiler Group 6.9%; Tradable 42.1% by minority shareholders
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Wuhan Boiler Organization Chart
Human Resource Jenny ZHANG Legal & Contract YANG Ning General Manager CHEN Chaoming Finance FENG Zheng Tendering ZHANG Dayong Sales BAI Xixin Lean & EHS PEI Hanhua General Service JIN Zhicheng Manufacturing WANG Quguang Project Management ZUO Zhihui Engineering WANG Xinhua Supply Chain LI Chenghai Production Quality CHEN Xiaoming Quality Operation Excellence Godfrey DAYO Effective from Nov 24, 2016
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WBC Product Portfolio Range Fuel Type Boiler Type Two Pass Tower CFB
100 MW 1,350 MW * * Oil-fired : up to 1,000 MW Bituminous Sub-bituminous Lignite (moisture <40%) Oil & Gas Coal-Fired Oil-Fired Tower Bituminous Sub-bituminous Lignite (all moisture level) 100 MW 1,350 MW * Hard Coal-Fired Lignite-Fired * Lignite Tower: up to 1,100 MW CFB Full range of fuels 100 MW 660 MW * PC SC 1300MW: B&W Rockport 2 (Order 1977) O&G SC 700MW: IHI CHITA II #2 (Order 1980) CFB SC 600MW: Dongfang Baima (order 2009) * Up to 660MW for lignite, higher for hard coal HRSG Drum All sizes of GE gas turbines Mills Full range of fuels for PC Boilers HP Mill up to HP1303 SM Mill up to SM 31 BW Mill up to dia. 4400mm
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Manufacturing Capability
WBC designs, manufactures and services sub- critical, supercritical, ultra-supercritical and A- USC steam boilers. Chinese Market: Boiler Proper, Overseas Market: Boiler Proper or Boiler Island. Certificates: ISO 9001 EHS certificates ASME “U” and “S” stamps EN ISO (by TUV) EN-PED Class A Chinese license for boilers EN 1090 Structural Steel Design WBC business covers full length of utility projects, from project development to project hand over to commercial operation, with a state of the art product manufacturing site.
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GE Wuhan Boiler References
10/11/2017 GE Wuhan Boiler References Pakistan Hubco 2 x 660 MW 254 Bar 568ºC / 571ºC Strong experience both domestically and globally for all boiler products Germany Mannheim 9 1x910 MW 285 Bar 600 ºC / 610ºC Poland Opole 2x900 MW 263 Bar 603 ºC / 611ºC China Taian 2 x 350 MW Binzhou Beihai 4 x 350 MW Jinchang 2 x 330 MW Hefeng 2 x 300 MW Huangshi 1 x 300 MW Chiping 2 x 300 MW Huizhou 2 x 330 MW Lanzhou 2 x 330 MW Liaoyuan 2 x 330 MW Luoyuan(USC) 2 x 660 MW Tangshan 2x58 MW Leiyang 1x300 MW Netherland Eemshaven 2 x 820 MW 299 Bar 600 ºC / 610ºC US PeeDee 1 1x640 MW 248 Bar 568 ºC / 596ºC Turkey Karabiga 2 x 660 MW 294 Bar 603ºC / 612ºC Slovenia Sostanj 1x600MW 291 Bar 600 ºC / 610ºC Mexico Altamira 2 x 165MW 131 Bar 540 ºC / 540ºC Mailiao(TW, USC) 2x600 MW Estonia Narva CFB 1x300 MW 174 Bar 541 ºC / 541ºC Saudi Arabia Yanbu 5 x 630 MW 258 Bar 542ºC / 540ºC Thailand Mae Moh 1x600 MW 285 Bar 605 ºC / 611ºC Malaysia Manjung 1x1000 MW 278 Bar 602 ºC / 603ºC Tanjung Bin 1 x 1000 MW Projects under execution Israel Ashalim 1 x 121 MW 170 Bar 585ºC UAE/Dubai Hassyan 4 x 660 MW 289 Bar 603 ºC / 612ºC Pakistan Thar II 2 x 330 MW 175 Bar 541 ºC / 541ºC Vietnam Thanglong 2 x 300 MW 174 Bar 541 ºC / 541ºC ABC Orders from Thermal Service ABC Main contracts by WBC 100% mfg OTD and no any LD claimed by customers
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New WBC- Main Product Manufactured (after 2007)
Delivery Plant Customer Output, MW Cycle, MPa/C/C Type Hassyan DEWA(UAE)/HEI x /603/ pass, USC Thar II ENGRO(Pakistan)/CMEC x /541/ CFB, Sub Hubco TEEG-ZEPC(Pakistan) x /568/ pass, SC Thanglong TLP (Vietnam) 2 x /541/541 CFB, Sub 2016 Mae Moh EGAT (Thailand) 1 x /605.6/ pass, USC Luoyuan Huaneng (China) x /605/623 Tower, USC Karabiga CENAL (Turkey) x /603/612 2-pass, USC Ashalim Megalim (Israel) x /585/NA CSR 2014/2015 Tai’an Guodian (China) x /571/ pass, SC 2014/2015 Altamira Isolux(Mexico) x /540/540 CFB, Sub 2014/2015 Opole ABD (Poland) 2 x /603/611 Tower, USC Binzhoubeihai Weiqiao x /540/541 2-pass, Sub 2013/15 Yanbu 3 SWCC (Saudi Arabia) 5 x /542/540 2-pass, SC 2012/13 Narva Eesti Energia AS (Estonia) 1 x /540/540 CFB, Sub 2012/13 TanjungBin 4 Malakoff (Malaysia) 1 x /602/603 2-pass, USC 2011/12 Manjung 4 TENAGA (Malaysia) 1 x /602/603 2-pass, USC 2011/12 Sostanj 6 TERMOELEK (Slovenia) 1 x /600/610 Tower, USC 2010/11 Mannheim 9 GKM (Germany) 1 x /600/610 Tower, USC 2010/11 Eemshaven A&B RWE Power AG (Netherland) 2 x /600/610 Tower, USC 2011/12 Jinchang GEPIC (China) 2 x /540/540 2-pass, Sub 2009/11 Hefeng State Grid (China) 2 x /541/540 2-pass, Sub 2008/09 Huangshi Huadian (China) 1 X /540/540 2-pass, Sub 2008/09 Chiping Xinfa Group(China) 2 x /540/540 2-pass, Sub 2008/09 Huizhou Guohua Power(China) x /541/540 2-pass, Sub 2007/08 Liaoyuan Datang (China) 2 x /543/542 2-pass, Sub
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New WBC- Main Product Manufactured (after 2007) – Thermal Service
/ Lanzhou 2 GEPIC (China) 2 x /540/540 2-pass, Sub 2007/08 PeeDee 1 SANTEE COOPER (US) 1 x /568/596 2-pass, SC 2013 Tangshan Banpu Banpu(Thailand) 2 x / pass(retrofit) 2014 Leiyang Datang(China) 1 x /540/ pass, Sub(retrofit) Mailiao FORMOSA(Taiwan) x /538/ pass, USC(retrofit) Delivery Plant Customer Output, MW Cycle, MPa/C/C Type
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通用电气武锅先进的技术 GE Wuhan Boiler Advanced Technology
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Single-flow factory to deliver world-class boilers
last edit: Straight Flow Manufacturing process 跨1: 再热器/过热器Bay 1: Reheater/Superheater 跨2: 省煤器/散管Bay 2:Economizer/Loose tube 跨3: 膜式壁 Bay 3: Panel workshop 跨4: 集箱 Bay 4: Header 跨5: 汽包 Bay 5: Drum 原材料货场 Raw material storage 机加车间 Machine shop 汽包射线探伤 X-ray bunker for drum 热处理炉Heating furnaces 喷丸 Shot blasting 油漆间 Painting cabin 材料研究所 Material Lab 主办公楼 Office building 单流向工厂,制造世界一流的锅炉产品 Single-flow factory to deliver world-class boilers 原材料 Raw materials 完工产品 Finished products 气瓶仓库 Gas bottle storage 危险品仓库 Hazardous waste storage 变电站 Substation 生产办公楼 Mfg. offices 18
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Straight Flow Manufacturing process
last edit: Straight Flow Manufacturing process 完工产品 Finished Goods 原材料 Raw Material Bay 5: Drums 跨五:汽包 16,400 m2 Bay 4: Headers 跨四:集箱 21,600 m2 Bay 3: Panels 跨三:膜式壁 21,600 m2 Bay 2: Economizers, Loose Tubes, Burners 跨二:省煤器、散管及燃烧器 21,600 m2 Bay 1: Superheater/Reheater heat exchangers 跨一:过热器、再热器 m2 600 m 36 m 456 m 北 N
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WBC Lab Capability Technical Cooperation
National accredited Laboratory certified to ISO/IEC 17025:2005, the first lab in domestic boiler industry. An accredited lab of Hubei Entry-Exit Inspection and quarantine Bureau. Technical Cooperation ASME Volume Ⅱ Chinese working group to promote Chinese material drawn into ASME code. China Special Equipment Inspection and Research Institute to conduct failure analysis; well-known universities and colleges to conduct material R&D; Steel mills to conduct new material property evaluation and new material localization; Future Cooperation with Thermal Service Material Test Failure Analysis Remaining Life Evaluation Condition Assessment Site test /witness technical problem solving
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Process Automation & Integration
Significant automation is ensuring repeatable quality standards for: Straight tube cut and prep (automated measure, cut, prep and marking) TIG/MAG straight tube and orbital welding System bender for elements Single tube bender for burner panels All supported by iGEMS Process automation results in robust processes that consistently produce quality products at a predictable rate. Automated Tube Cut and Preparation line Pretreatment of the tubes before welding. 20K welds output per month Input drawing, cutting, beveling and polishing per designated length 4 sets of bending device and 1 set of heating device Controlled by CNC automatically, 30k bends output per month Most advanced benders in the world Tube to tube connect welded automatically Can weld any material for boiler. 10K butt welds output per month High quality: Reject rate lower than 0.5% Designated data link to the bender directly, 3D auto CNC controlled. More than 300 different kinds of 3D single tube can be combined together perfectly Single tube bender Straight tube prep TIG/MAG System bender 21
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Welding Technology Welding is the most critical and essential process in boiler making Wuhan’s reference covering all low to high grade/new materials and major international Codes applied in global utility boiler industry More than 491,284 shop welds by new WBC have been in service and there is zero failure due to defective welds. Complete development, training, analysis and technical support capability. Significant level of automation and machine controlled welding processes. Quality is built into our design and processes and not dependent on testing alone. 70% to 80% of our pressure retaining welds are machine welded (automated). Welding Training Welding Automation Welding Technology Welding Quality In house welder training Centre & welder certification covering all Code requirements Straight tube welding Orbital welding Nipple welding In-house laboratory, welding development for all material and codes Reject rate <2% Zero weld shop leakage on site 22
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Straight-Tube-Welding First Pass Yield (FPY)
Testing equipment using the latest technology that is accepted globally. Average FPY in the last 14 months is 99.95%. Sigma value is 4.8 Process capability (CPk) is 1.6 23
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Testing equipment using the latest technology that is accepted globally.
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Digital RT & QC Digital RT & Quality Control:
It is accepted by all governance Codes and customers (the only one in China boiler industry accepted by EN authority) GE shops and WBC have the highest use of advanced DIGITAL REAL TIME RT equipment in the boiler industry Compared to film radiography, productivity increased by 700% and a cycle time reduced by 600% Testing equipment using the latest technology that is accepted globally. Digital Radiography in accordance with ISO “Non-destructive testing of welds – Radiographic testing – Part 2: X- and gamma-ray techniques with digital detectors. TUV Sud, TUV Rhineland & UDT (Poland) certified. 25
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Stainless Steel Tube ID Shot Peening
Clean up oxidation layer of steel tube inner surface Increased corrosion resistance, fatigue resistance and surface hardness of material Produce a compressive residual stress layer and modify mechanical properties of metals Prolonged material & product life time Shot-peened S304H can replace material of higher level and higher price, or perform much longer life time than the un-peened material. Thinner Oxidation Layer Un-peened 304H vs Peened at 600°C for 3000 hours No Visible Oxidation Layer Un-peened 304H vs Peened at 650°C for 10,000 hours Again, automated processes that allows us to have consistent and predictable results. 维氏硬度: 600HV30/20---采用30千克力的试验力,保持20秒,得到硬度值为600。 Requirement: The hardness values of the shot-peening area are to be at least 100 HV 0.1 higher than the average value of the base material. Proof of shot-peening treatment on the inner tube surface with respect to uniformity across the entire tube circumference and a minimum impact depth of 70 μm on the micro section. WBC was the first boilermaker in the world to have in house Shot Peening capability for supercritical boilers. Our shot peening process and machines were co- developed with strategic supplier for our product. Capability: max 15m (max 10m the other suppliers) Material: Stainless steel incl. Super304H 26
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Continuous Manufacturing R&D
Robotics and advanced welding processes New material development Induction heating for water-wall panels Digital data collection and management And we continue to look for better ways to improve our products and processes.
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通用电气武锅先进的管理 GE Wuhan Boiler Advanced Management
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Boilers Manufacturing-Operational Excellence
NCR detection & prevention Lead Time Reduction Cost Reduction for Major Products Site deliveries modularized Increase awareness and actions 8D with focus on top systemic quality issues For Plants/Boilers TMSys Lean Manufacturing Boiler Modularization and Erection Strategy AZDP GE Zero Deviation Plan GMQS: Global Manufacturing Quality System Manufacturing R&D Knowledge Transfer iGEMS Brick Boiler Design 5 S Based on Sector targets we have define set of Steam specific, comprehensive programs for all d2E pillars. Several actions with dedicated teams have been launched in all product Lines. Today, I would like to explain you in more details 2 examples of recent achievements / best practices in cost reduction / standardization programs Design for Manufacturing Product Platform Development Develop / train EHS Community
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Digital Industry-iGEMS Process
Create AutoCAD 3D model ENGINEERING Export to iGEMS to generate iGEMS model Give design parameters such as bending, scarfing etc. BOM for procument Edit traveller & WC report, assign shop hours MMI Release the relevant reports’ which generated by iGEMS automatically, to workshop Workshop can simulate the manufacturing process MANUFACTRUING Fabricate and assembly according to iGEMS reports An internally developed robust CAD CAM process that starts in the initial design phase and carries through to the manufacturing work centers.
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Quality Management System - GMQS
2017/11/10 Quality Management System - GMQS GMQS - Global Manufacturing Quality System Customer Commitment FMEA Mistake-Proofing MSA SPC Cpk, Cmk NCR CoPQ Audits Manufacturing Process Development Manufac- turing Partial advanced methods and tools Non- conformance Management Manufacturing Process Monitoring Target Manufacturing quality system standardization Manufacturing process capability stable promotion Product quality continuous monitoring Market competitiveness keeping robust Ensure Customer Satisfaction by building manufacturing capability focusing on QA rather than QC
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Quality Management System – GE One Boiler Supplier Management
2017/11/10 Quality Management System – GE One Boiler Supplier Management Boiler Supplier Qualification Approval Committee (Boiler Level Engineer, Quality, Supply Chain) Centre Transition Core Teams Key Commodities to be approved by SQAC Wuhan Windsor Stuttgart Delhi -2 Pass -CFB -Tower -2 Pass -Tower -2 Pass -CFB Target setting Global Sourcing Strategy Review Key Commodity SQA Validation of action plans -CFB Supplier Commercial Evaluation NDA CSR SPIQ FEF SCC SGDC SCE Result SQA Supplier Qualification Approval SCM Director Supplier QEHS Qualification ISO system Quality system EHS QEHS Report QPI Director Supplier Product Qualification Conformity with GE technical requirements Key process PQ Report Engineering Director GB Code ASME Code EN Code IBR Code Key User maintain PowerSource Database Global Supplier Management Database PowerSource
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Integrated Advanced Technology, Design and Manufacturing
Original Technology International Design Intelligent Manufacturing TECHNOLGY CENTERS Windsor, GE in USA: Two-pass Boilers Stuttgart, GE in Germany: Tower Boilers Massy, GE in France: CFB Boilers Centre Actions One Boiler Stuttgart Windsor India Massy Resource Planning and Manufacturing Coordination Standard WBS / Division of Work One Process Knowledge Transfer: Provider and Receiver Wuhan Animation note: click once to reveal answers DO Give your employees the link to the Quality pages. Keep the responses that your team gave in the OVER TO YOU work in your mind and congratulate them when they’ve identified a key feature. You can tell them that they already know what features are important and it’s now vital to delivering them every time. SAY To remind you what Quality is – we describe it as consistently meeting customer commitments on time and on budget. This is important whether we have direct contact with customers or if our customers are internal ones within our business... They all matter and should be focused on. Some simple bullet points to remind us about how we can use Quality practices to improve: Responsiveness – is about speed; on time, at the right time Reliability – is about delivering what we say we will On time delivery – is about delivering when the customer expects us to not when is best for us Durability – is about providing a high quality product or service that stands the test of time Price – is about a fair competitive price for us and the customer for the work which we do for them Performance – is about consistently and constantly delivering to the highest standards Dependability – is about doing what we say we will without any problems Right the first time – is about delivering a Quality product or service without any errors or issues Achieve schedule – is about keeping to our contractual obligations Availability – is about having a total customer focus when they need us This is what Quality is about and represents how we can say we are dedicated to excellence (d2e). 33
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Factories Load Chart – Wuhan By Quarter
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