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

April, 2007

TurboCare Sp. z o.o.

TECHNICAL OVERVIEW

Privileged & Confidential –

TurboCare sp. z o.o. – structure

SIEMENS AGSIEMENS AG WIBREM Sp. z o.o

WIBREM Sp. z o.o

TurboCare Sp. z o.oTurboCare Sp. z o.o

PRUFTECHNIK WIBREM

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.


TurboCare sp. z o.o. - employment

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1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

Year

EMPLOYMENT


TurboCare SpaTurboCare Spa

SerWestcaSerWestca

Masaood John BrownMasaood John Brown

MJB InternationalMJB International

TurbTurboCare LtdoCare Ltd ThailandThailand

TurboCare TurboCare Gas Turbine ServicesGas Turbine Services

TurboCare Pty LtdTurboCare Pty Ltd

Turbine Services Turbine Services LimitedLimited

TurboCareTurboCare Inc Inc

TTCC Pol Polandand

TurboCare InternationalTurboCare International

TurboCare – locations map

TurboCare Sericos em TurboCare Sericos em Turbomaquinas LtdTurbomaquinas Ltd

Kadon Electro Kadon Electro Mechanical Service LtdMechanical Service Ltd


TurboCare companies

TurboCare Inc

TurboCare International, GmbH


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


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

1998

2006


inside of workshop


LP rotor – 36t ready for sandblasting


machines in workshop – 1

Heavy horizontalboring machine – to 65 t.

Horizontal boring machine



Heavy lathe L = 8 m D = 2850 mm

Load – 30 t

LP rotor of 120 MW turbine machining



Horizontal lathe D = 3500 mm, Load = 65 t

Heavy boring machine


turbines in workshop

Field for turbine assembly


work in situ at power plant

BBC 300 MW turbine


work in situ

TurboCare uses own containers for site preparation.

Container city in Power Plant


work in situ

Tool storage near turbine

Mobile lathe and mobile mill near turbine.


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


TurboCare installed in 2002 for Alstom – 3 skids with gas compressors system in Poland.

instalation


Major overhaul of 200 MW turbo – generator of LMZ design

steam turbine overhaul


gas turbine overhaul

VANTA PP – FinlandGas turbine 80 MW


Diaphragm blade assembling

Compressor & turbine New blades of turbine rotor


hydro turbine overhaul


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.


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


vibration diagnostic

►Vibration measurement

►Vibration analyze

►Balancing at site

►Analyze of blades vibration


Grit blasting with cooper slag sand, aluminum oxide and

glass pearls

grit blasting


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;


Work in high temperature with high stresses is the

source of cracks of turbine parts.

non-destructive testing


► 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


►Cleaning, NDT,

cracks

removing;

►Welding repair;

►Dimensions control;

►Machining;

►Bolts replacement;

►Assembling.

turbine casings overhaul


After overhaul turbine casings are ready for assembly.

turbine casings overhaul


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.

turbine casings material structure rectify

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


turbine rotors straightening


Blades assembly

blades replacement


TurboCare assemblies all kind of turbine blades.

blades replacement


Siemens design blades assembly

blades replacement


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


Mobile boring machine WK-2

Bore diameter – from 1300 to 4000 mm

Bearings distance – 5030 mm

Weight – 17 000 kg

mobile machines


LP casing of 200 MWturbine machining at site

mobile machines


Mobile boring machine for turbine casings

The biggest in the worldD = 6000 mm, L = 10000 mm

TurboCare Sp. z o.o. design and manufacturing


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


mobile machines


Pipes external work.

Inlet of steam pipes, with piston rings type sealing, need external surface machining for bushes replacement.

After machining

mobile machines


Milling machine for surface and grooves

machining

mobile machines


Machine for couple bores turning

Overhaul of coupling needs machining of bolt holes with knife when bushes are installed.

mobile machines


Drilling machine with swivel head.

mobile machines


mobile machines


laser alignment of turbines


AEG turbine modernization


Oil filtering and flusing mobile system

oil purity control and flushing


Low speed balancing at site with mobile machine

High speed balancing with Schenck machine in Brno

turbine rotors balancing


turbine overhaul in workshop


turbine overhaul in workshop

Preliminary assembling in TurboCare workshop

Thank you for your attention

WROCLAW – CITY OF TurboCare Sp. z o.o. LOCATION

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

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