Transcript Slide 1

TurboCare Sp. z o.o.
TECHNICAL OVERVIEW
April, 2007
TurboCare sp. z o.o. – structure
SIEMENS AG
WIBREM Sp. z o.o
80%
shares
20%
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PRUFTECHNIK
WIBREM
TurboCare Sp. z o.o
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 2
TurboCare sp. z o.o. - employment
EMPLOYMENT
300
250
200
150
100
50
0
1992
1993
1994
1995
1996
1997
1998
1999
2000
Year
Privileged & Confidential – Page 3
2001
2002
2003
2004
2005
2006
2007
TurboCare – locations map
Kadon Electro
Mechanical Service Ltd
Turbine Services
Limited
TurboCare International
TurboCare Inc
TC Poland
TurboCare Spa
TurboCare
Gas Turbine Services
SerWestca
Masaood John Brown
MJB International
TurboCare Sericos em
Turbomaquinas Ltd
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TurboCare Ltd
Thailand
TurboCare Pty Ltd
TurboCare companies
TurboCare Inc
TurboCare International, GmbH
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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 6
TurboCare sp. z o.o. turbine overhaul workshop
1998
► 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
2006
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inside of workshop
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LP rotor – 36t ready for sandblasting
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machines in workshop – 1
Horizontal boring machine
Heavy horizontal
boring machine – to 65 t.
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machines in workshop – 2
LP rotor of 120 MW turbine machining
Heavy lathe
Privileged & Confidential – Page 11
L=8m
D = 2850 mm
Load – 30 t
machines in workshop – 3
Horizontal lathe
D = 3500 mm, Load = 65 t
Heavy boring machine
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turbines in workshop
Field for turbine assembly
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work in situ at power plant
BBC 300 MW turbine
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work in situ
TurboCare uses own containers for site
preparation.
Container city in Power Plant
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work in situ
Tool storage near turbine
Mobile lathe and mobile mill
near turbine.
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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
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instalation
TurboCare installed in 2002 for Alstom – 3 skids with gas compressors system in Poland.
Privileged & Confidential – Page 18
steam turbine overhaul
Major overhaul of 200 MW turbo – generator of LMZ design
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gas turbine overhaul
VANTA PP – Finland
Gas turbine 80 MW
Privileged & Confidential – Page 20
Diaphragm blade assembling
Compressor & turbine
Privileged & Confidential – Page 21
New blades of turbine rotor
hydro turbine overhaul
Privileged & Confidential – Page 22
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 23
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
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vibration diagnostic
►Vibration measurement
►Vibration analyze
►Balancing at site
►Analyze of blades vibration
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grit blasting
Grit blasting with cooper slag
sand, aluminum oxide and
glass pearls
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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;
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non-destructive testing
Work in high temperature
with high stresses is the
source of cracks of turbine
parts.
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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
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turbine casings overhaul
► Cleaning, NDT, cracks
removing;
► Welding repair;
► Dimensions control;
► Machining;
► Bolts replacement;
► Assembling.
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turbine casings overhaul
After overhaul turbine casings
are ready for assembly.
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turbine casings material structure rectify
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.
Privileged & Confidential – Page 32
Crystal grain before and after
normalization of turbine casing
material.
turbine rotors straightening
Run-out before straightening – to 5,40 mm
Run out after straightening – max 0,12 mm
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turbine rotors straightening
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blades replacement
Blades assembly
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blades replacement
TurboCare assemblies all kind of
turbine blades.
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blades replacement
Siemens design blades assembly
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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 38
mobile machines
Mobile boring machine WK-2
Bore diameter – from 1300 to 4000 mm
Bearings distance – 5030 mm
Weight – 17 000 kg
Privileged & Confidential – Page 39
mobile machines
LP casing of 200 MW
turbine machining at site
Privileged & Confidential – Page 40
Mobile boring machine for turbine casings
The biggest in the world
D = 6000 mm, L = 10000 mm
TurboCare Sp. z o.o. design and manufacturing
Privileged & Confidential – Page 41
mobile machines
Diffusers boring machine WD -1
Bore diameter 50 – 1000 mm
Depth of machining to 1300 mm
Machining of the cylindrical and axial
surfaces
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mobile machines
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mobile machines
Pipes external work.
Inlet of steam pipes, with piston rings
type sealing, need external surface
machining for bushes replacement.
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After machining
mobile machines
Milling machine for
surface and grooves
machining
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mobile machines
Machine for couple bores turning
Overhaul of coupling needs machining
of bolt holes with knife when bushes
are installed.
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mobile machines
Drilling machine with swivel head.
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mobile machines
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laser alignment of turbines
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AEG turbine modernization
Privileged & Confidential – Page 50
oil purity control and flushing
Oil filtering and flusing mobile system
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turbine rotors balancing
Low speed balancing at site with
mobile machine
High speed balancing with Schenck
machine in Brno
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turbine overhaul in workshop
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turbine overhaul in workshop
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turbine overhaul in workshop
Preliminary assembling in
TurboCare workshop
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Thank you for your
attention
WROCLAW – CITY OF TurboCare Sp. z o.o. LOCATION