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TurboCare Sp. z o.o. TECHNICAL OVERVIEW

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% shares. PRUFTECHNIK WIBREM . TurboCare Sp. z o.o.

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TurboCare Sp. z o.o. TECHNICAL OVERVIEW

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

  2. TurboCare sp. z o.o. – structure SIEMENS AG WIBREM Sp. z o.o 80% shares 20% shares 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 majorindustry OEMs.

  3. TurboCare sp. z o.o. - employment

  4. TurboCare – locations map Turbine Services Limited TurboCare International Kadon Electro Mechanical Service Ltd TurboCare Inc TC Poland TurboCare Spa TurboCare Gas Turbine Services TurboCare Ltd Thailand Masaood John Brown MJB International SerWestca TurboCare Pty Ltd TurboCare Sericos em Turbomaquinas Ltd

  5. TurboCare Inc TurboCare International, GmbH TurboCare companies

  6. 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

  7. TurboCare sp. z o.o. turbine overhaul workshop • 2300 m2 • Overhead crane 50 t • Toolstore • Social and office area • Electrical supply system 1,2 MW • Heating system 800 kW • Roads for heavy transport 1998 2006

  8. inside of workshop

  9. LP rotor – 36t ready for sandblasting

  10. machines in workshop – 1 Horizontal boring machine Heavy horizontalboring machine – to 65 t.

  11. machines in workshop – 2 LP rotor of 120 MW turbine machining Heavy lathe L = 8 m D = 2850 mm Load – 30 t

  12. machines in workshop – 3 Horizontal latheD = 3500 mm, Load = 65 t Heavy boring machine

  13. turbines in workshop Field for turbine assembly

  14. work in situ at power plant BBC 300 MW turbine

  15. work in situ TurboCare uses own containers for site preparation. Container city in Power Plant

  16. work in situ Tool storage near turbine Mobile lathe and mobile mill near turbine.

  17. installation TurboCare is ready for: • assembling of old or new turbinesonnew foundation • precision leveling of machine frames • transport of heavy units to plants

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

  19. Major overhaul of 200 MW turbo – generator of LMZ design steam turbine overhaul

  20. gas turbine overhaul VANTA PP – FinlandGas turbine 80 MW

  21. Diaphragm blade assembling Compressor & turbine New blades of turbine rotor

  22. hydro turbine overhaul

  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 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

  25. vibration diagnostic • Vibration measurement • Vibration analyze • Balancing at site • Analyze of blades vibration

  26. grit blasting Grit blasting with cooper slag sand, aluminum oxide andglasspearls

  27. 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;

  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 videoregistrationand dimensionsmeasuringsystem; • TV camera – F30mm, 11 m long

  30. turbine casings overhaul • Cleaning, NDT, cracks removing; • Welding repair; • Dimensions control; • Machining; • Bolts replacement; • Assembling.

  31. turbine casings overhaul After overhaul turbine casings are ready for assembly.

  32. 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. Crystal grain before and after normalization of turbine casing material.

  33. turbine rotors straightening Run-out before straightening – to 5,40 mm Run out after straightening – max 0,12 mm

  34. turbine rotors straightening

  35. blades replacement Blades assembly

  36. blades replacement TurboCare assemblies all kind of turbine blades.

  37. blades replacement Siemens design blades assembly

  38. 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

  39. mobile machines Mobile boring machine WK-2 Bore diameter – from 1300 to 4000 mm Bearings distance – 5030 mm Weight – 17 000 kg

  40. mobile machines LP casing of 200 MWturbine machining at site

  41. Mobile boring machine for turbine casings The biggest in the worldD = 6000 mm, L = 10000 mmTurboCare Sp. z o.o. design and manufacturing

  42. 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

  43. mobile machines

  44. mobile machines Pipes external work. Inlet of steam pipes, with piston rings type sealing, need external surface machining for bushes replacement. After machining

  45. mobile machines Milling machine for surface and grooves machining

  46. mobile machines Machine for couple bores turning Overhaul of coupling needs machining of bolt holes with knife when bushes are installed.

  47. mobile machines Drilling machine with swivel head.

  48. mobile machines

  49. laser alignment of turbines

  50. AEG turbine modernization

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