Engineered solutions for Turbine and Generator overhauls, repairs

Engineered solutions for Turbine and
Generator overhauls, repairs and uprates
Helsinki
December 13th, 2012
Privileged & Confidential
Agenda
Products, Services and Organisation
What makes TurboCare a different ISP?
Engineered solutions for Maintenance,
Overhauls, Repairs and Rerates
& Confidential Page 2
PrivilegedPrivileged
& Confidential
Agenda
Products, Services and Organisation
What makes TurboCare a different ISP
Engineered solutions for Maintenance,
Overhauls, Repairs and Rerates
& Confidential Page 3
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& Confidential
Siemens Energy Organization
Energy
Sector
Oil&&Gas
Gas
Oil
FossilPower
Power
Fossil
Generation
Generation
Renewable
Renewable
Energy
Energy
FossilPower
Power
Fossil
Generation
Generation
Energy
Energy
Service
Service
Power
Power
Transmission
Transmission
Power
Power
Distribution
Distribution
Industrial
Industrial
Application
Application
TurboCare Group:
World's largest independent service provider offering aftermarket service and repair
solutions to owners and operators of rotating equipment manufactured by major industry
OEMs.
Privileged & Confidential
TurboCare European Facilities
Our Story
Our Customers
Locations
TurboCare B.V.
Netherlands
TurboCare International
UK
TurboCare Sp. z.o.o.
Poland
TurboCare S.A.
Poland
TurboCare S.p.A.
Italy
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The TurboCare Story l Customers
Our Customers
Utility Market
–
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Fossil
Geothermal
Nuclear
Biomass
Industrial Market
– Oil & Gas
– Pulp & Paper
– Chemical Processing
Locations
People
Products and Services
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Products and Services
Gas Turbines >
Steam Turbines >
Electrical Machinery >
Compressors >
World class capabilities in engineering, manufacturing
and service of turbomachinery with a “customer first”
approach for fast and reliable service.
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–
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Inspections
MO / Field Service
Component Repairs
New Components
Rerates
Efficiency improvements
TurboCare GT Capabilities Overview
GENERAL
ELECTRIC
Frame 3
WESTINGHOUSE
FIAT
W101
TG7
Frame 5
W191
TG16
Frame 6B
W251 up to B8
TG20
Frame 7B~EA
W501 up to D5
TG50 up to D5
701 DU
Frame 7FA
Frame 9E
MHI
701F
M191
M251
501F
701D
701F
Privileged & Confidential Page 8
ABB / ALSTOM
GT11D5
GT13E2/E1
Steam Turbine Capabilities
ABB Stal, ACEC, Alstom, Ansaldo, BBC, Franco Tosi, Escher Wyss, Fuji, GE, LMZ,
Mitsubihi (MIH), Oerlikon, Skoda, Thermodyne, Toshiba, Zamech
Privileged & Confidential – Page 9
Generator Services Capabilities Overview
Generator Capabilities
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Diagnostics
Repairs
Rewinds
Components
Balancing
Upgrades
Field service on generators
TurboCare - Generators - Page 10
Sample OEM’
OEM’s:
 ABB
 GE
 Mitsubishi
 Alsthom
 GEC
 AC
 Westinghouse
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DOLMEL
SKODA
ZAMECH
OERLIKON
STAL
ASEA
Curtis Wright
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GANZ
ANSALDO
FUJI
ELIN
BBC
EM
Brush
Agenda
Products, Services and Organisation
What makes TurboCare a different ISP
Engineered solutions for Maintenance,
Overhauls, Repairs and Rerates
Privileged
& Confidential Page 11
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& Confidential
Key Capabilities make the difference
Gas Turbines >
Steam Turbines >
Electrical Machinery >
Compressors >
World class capabilities in engineering, manufacturing
and service of turbomachinery with a “customer first”
approach for fast and reliable service.
Privileged & Confidential
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Inspections
Reverse Engineering
Engineering
Re-use of components
Lead times
Manufacturing facilities
High Speed Balancing
Steam Turbine casing Inspections and Repairs
Non-contact areas
– Example of blue check results
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Steam Turbine casing Inspections and Repairs
THESE DIAMETERS TO BE
CONCENTRIC WITH A TO
WITHIN 0.002”
A
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Phased Array (ultrasonic) Inspection
90
E
D
C
B
A
180
0
F
270
Calibration
blocks
2
1 Scanning
positions
3
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Generator inspections / diagnostics
 AC & DC High Voltage
 Partial Discharge and Tan Delta
 BUMP TEST (Natural frequncies
measurement)
 Thermovision core mapping
 ELCID (Electromagnetic Core
Imperfection Detection)
 RSO (Recurrent Surge Oscillgraph)
 RBE (Rotor Bore Examination)
 NDT (Non Destructive Tests)
 Stator Wedge Tightness Mapping
 Other tests required by Customer
TurboCare &
- Generators
- Page 16
Privileged
Confidential
Generator Reverse Engineering
FARO Arm
Obtaining the
Calculations
Dimensional
Measurement
geometrical model
and modeling
quality checks
TurboCare &
- Generators
- Page 17
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Confidential
Generator Engineering Capabilities
KNOW-HOW
• Highly-qualified and experienced
engineering staff
• R&D Projects
• Continuous co-operation with leading
universities and research institutes
• Up-to-date software engineering
(CAD/CAM/CAE: incl. Pro/Engineer,
AutoCad, Pro/Mechanica, Pro/NC,
Ansys Multiphisics, Mathcad)
• Reverse Engineering Capabilities discovering the technological
principles of objects through
computer analysis of its structure,
function and operation in CAD
environment
Company
Products & Services
Experience
Privileged &&Confidential
- Page 18
Privileged
Confidential
Reverse Engineering Process
Blade sample is scanned using a portable laser scanner,
a white light scanner or a Coordinate Measuring Machine
(CMM).
Portable CMM
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White light Scan
Reverse Engineering
BLADE SAMPLE
POLYGON RENDERING
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POINT CLOUD
3D SOLID MODEL
TurboCare – Airfoil Engineering
3-D Solid model spawns all downstream
mfg activity.
DRAWING
MANUFACTURING
3D SOLID MODEL
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QUALITY CONTROL
Reverse Engineering
Through the use of our modern technology and our extensive
experience in the blading market, we are able to take severely
damaged samples, reconstruct an accurate model and manufacture
new blades in a matter of days.
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Key Engineering Capabilities
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Turbine modernizations, upgrades, and rerates
– Turbine Re-Applications
– Simple Cycle to Combined Cycle
Conversions
Mechanical & thermodynamic design
Blade Failure Analysis & Redesign
Finite Element Stress & Heat Transfer
Analysis
Unit and Rotor Dynamic Analysis and
support
Weld repair technology
Rapid failure analysis and assessment
Our Engineering organization includes well over 100
Engineers with experience on virtually every OEM
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Airfoil Manufacturing Facilities
Winston-Salem, North
Carolina
– 305,000 sq. ft. facility
– Staffed 24/7
– ISO 9001:2000
Certified
Manchester, Connecticut
– 26,000 sq. ft. facility
– Staffed 24/7
– ISO 9001:2000
Certified
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Generator Coil Manufacturing Capabilities
TC Poland has existing coil manufacturing capacity
for conventional, inner cooled and water cooled
coils. The facility has considerable reverse
engineering capability.
An expansion of the facility is in progress to
increase the manufacturing capacity production of
stator coils. The facility also manufactures “Cshaped” rotor coils with a designated CIM facility.
TurboCare &
- Generators
- Page 25
Privileged
Confidential
Generator Machining Capabilities
Heavy lathes, machining to diameter 2,5 m, length to 12 m and
weight to 80 tons
Vertical lathes and vertical boring mills
Milling and planing machines
TurboCare &
- Generators
- Page 26
Privileged
Confidential
Generator High Speed Balance facility
High Speed Balance by TurboCare
 Weight of balanced rotors
between 5 and 80 tons
 Hot balancing capability
 Max rotor diameter
4 meters
 Max balancing rotation
speed 4.500 rpm
TurboCare &
- Generators
- Page 27
Privileged
Confidential
Agenda
Products, Services and Organisation
What makes TurboCare a different ISP
Engineered solutions for Maintenance,
Overhauls, Repairs and Rerates
Privileged
& Confidential Page 28
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& Confidential
Baymina LP Turbine
Casing Analysis
Diffuser Repair
ABB 320 MW
Privileged & Confidential
LP Configuration
• Eroded area 6-8 mm deep into call
• LP casing wall – cast iron material
Privileged & Confidential
Casing Model
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LP barrel section modeled in ANSYS as 3-D solid to investigate wall
stresses in eroded area
Casing split at horizontal joint- Upper and lower halves free to move
independently
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Pressures on Casing
• Assumed pressure ratio
across stage 3.5 to 1
• Tip pressure reaction
assumed to be 50%
• Saturated temperatures
at pressures shown in
figure
• Minimum casing wall
thickness near eroded
region estimated to be 40
mm
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FEA Mesh at Erosion Region
• The eroded region model as semi-circle with refined
mesh density
• Stress concentration for radius of eroded area included
calculated peak stress
• Four notched regions analyzed to represent increased
level of erosion over time.
– 4 mm, 10 mm, 20 mm and 30 mm (10% to 75% of wall
thickness)
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Stresses in Eroded Casing Wall
• Eroded depth 4 mm – peak stress 18.2 MPa (2639 psi)
• Eroded depth 10 mm – peak stress 16.1 MPa (2331 psi)
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Stresses in Eroded Casing Wall
• Eroded depth 20 mm – peak stress 19.2 MPa (2777 psi)
• Eroded depth 30 mm – peak stress 27.8 MPa (4031 psi)
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Stresses in Eroded Casing Wall
Peak Stress vs. Erosion Depth
40
Peak Stress - MPa
35
30
25
20
15
10
5
0
0
10
20
30
40
Depth - mm
• Cast iron ultimate tensile strength estimated to be 170 MPa
(24 KSI) to 200 MPa (29 KSI)
• Factor of safety range on peak stress between 6 to 10
Privileged & Confidential
Baymina Project
Project: 320MW Alstom turbine in Baymina Turkey in 2009.
Welding repair: Welding to cast iron LP casing protective shield from
austenitic steel against Washing erosion.
TurboCare Sp.Zoo developed a qualified special welding technology for
combination of welded materials:
- turbine casing - cast iron EN GJS 400-15
- protective shield - austenitic steel X6CrNiTi 18-10
- nickel base filler metal
Blade Vane
Casing
Washing erosion area
Water flow marks
The area of casing damage
Privileged & Confidential
Macro photography of casing
washing erosion damage
Baymina Project
Portable boring machine WK5 in preparation for Baymina
Project.
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Baymina Project
Boring machine WK5 during LP casing machining.
Privileged & Confidential
Baymina Project
austenitic shield
welds
LP casing
„Weld preparation” machining
on portable boring machine
Casing view after welding
austenitic shields ( inserts )
casing
Penetrant NDT test after welding
Privileged & Confidential
Repaired area of the casing
after finished machining
Steam Turbine References Finland
Alholmens Kraft Ab
Lahti Energia Oy
Helsingin Energia
Salmisaari
Privileged & Confidential
Generator reference
Ferrybridge Power Station, UK
MANUFACTURE AND DELIVERY
OF NEW INNER FRAME
GENERATOR STATOR
Customer: Ferrybridge Power
Station,
UK
OEM: Parsons/TurboCare
Steam turbine driven
Rated Power: 500 MW
Hydrogen / Water Cooled
Works performed:
08.2008 – 01.2011
Ferrybridge
Privileged &&Confidential
- Page 42
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Confidential
Generator reference
Ferrybridge Power Station , UK
 Frame manufacturing
 Installation of stator core
and winding
 Assembly of phase connections
and insulation boxes
 Final tests and transportation
Ferrybridge
Privileged &&Confidential
- Page 43
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Confidential
Generator reference
KOZIENICE POWER PLANT, POLAND – TURBOSET LIFETIME EXTENSION
DESIGN, MANUFACTURE AND
DELIVERY OF NEW SPARE
GENERATOR STATOR
Customer: Kozienice Power
Station, Poland
OEM: TurboCare (Energoserwis
S.A.)
Steam turbine driven
Rated Power: 560 MW
Hydrogen / Water Cooled
Works performed:
18.07.2007 – 23.03.2009
Kozienice
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- Page 44
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Confidential
Generator reference
Almaraz PP, SPAIN – STATOR FRAME MANUFACTUIRNG
DESIGN, MANUFACTURING,
DELIVERY OF NEW STATOR
INNER AND OUTER FRAME
 Custmer: ALMARAZ PP, SPAIN
 Rated Power: 1000 MW
 Hydrogen/Water Cooled
 OEM: Siemens
 Frame manufacturing :
July, 2007 – October, 2008
WINDING ON SITE OF
NEW GENERATOR STATOR
 Stator Winding: September,
2009 – December 2009
Almaraz
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- Page 45
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Confidential
Generator reference
TRBOVLJE PP, SLOVENIA – STATOR UPGRADE AND ROTOR MODERNIZATION
 Customer: TRBOVLJE PP,
SLOVENIA
 Dec ’04 – Mar ’05 (ROTOR)
Factory rotor rewind
 Nov ‘08 – Jun ’09 (STATOR)
On-site restack & rewind
Generator power output increased up
to 130MW
Manufacturer: Dolmel
Type: TGH-120
Rating: 13,8 kV; 120 MW
Hydrogen cooled
Trbovlje
Privileged &&Confidential
- Page 46
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Confidential
Generator reference
TELUK GONG MELACA , MALAYSIA – 15 YEARS OF ROTOR OPERATION TIME EXTENSION
GENERATOR ROTOR ON-SITE
REWIND, STATOR REPAIR &
COMMISSIONING
Customer: POWERTEK Berhad &
TNB REMACO, Malaysia
Rated Power: 137 MVA; 15 KV
Air-Cooled
TYPE: T240-370
OEM: ALSTHOM
Rotor Delivery: 15.08.2010 – 27.11.2010
Stator Delivery: 27.02.2011 – 05.03.2011
Privileged & Confidential
Recent Generator Projects
DEIR AAMAR PP, LEBANON
GENERATOR MAJOR OVERHAUL
AND STATOR REWIND
Customer: YTL Power Service
Lead Time:
26.10.2011 – 20.12.2011
OEM: Ansaldo
Type: WY21Z-097LLT
Rating: 185 MVA; 14.7 kV
Air-Cooled
Privileged &&Confidential
- Page 48
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Confidential
Generator reference
EÜAS AMBARLI PP, ISTANBUL - TURKEY
REPAIR OF UNIT 4 & 5 GENERATORS
Replacement of stators core end packs
Delivery of U5 new stator winding
Renewal of U4 stator winding
Stators on site rewind
U4 rotor inspection with retaining rings
and wedges replacement
U5 rotor rewind with renewed copper,
retaining rings replacement
Generator components repair: bearings,
H2 rings, oil seal rings, brushgears.
OEM: Oerlikon, type 210 S 800 H4
Rating: 150 MW; 15 kV
Hydrogen cooled
Privileged &&Confidential
- Page 49
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Confidential
Experience – Key Projects Finland
Lahti PP, Finland, 2005
167 MVA Ganz rotor rewind
H. Energia Hanasaari, Finland, 2010
110 MW Skoda rotor rewind
Tampere Energy, Finland, 2009 & 2010
72 MVA B. Borsig rotor rewind (2 units)
Helsingin Energia, Finland, 2010
188 MVA, BBC rotor inspection
StoraEnso, Finland, 2007
25 MVA, ASEA rotor rewind
Oulun Energia, Finland, 2009
80 MW Ganz rotor rewind
Loviisa NPP, Finland 2012
4 x replacement of rotor
Company
Capabilities
Products & Services
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THANK YOU !!
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