engineered solutions for turbine and generator overhauls ... · pdf fileengineered solutions...

Privileged & Confidential
Engineered solutions for Turbine and
Generator overhauls, repairs and uprates
Helsinki
December 13th, 2012

Privileged & ConfidentialPrivileged & Confidential Page 2
AgendaAgenda
Products, Services and Products, Services and OrganisationOrganisation
What makes What makes TurboCareTurboCare a different ISP?a different ISP?
Engineered solutions for Maintenance, Engineered solutions for Maintenance,
Overhauls, Repairs and ReratesOverhauls, Repairs and Rerates

AgendaAgenda
What makes What makes TurboCareTurboCare a different ISPa different ISP

Siemens Energy Organization
Oil & GasOil & Gas Fossil Power GenerationFossil Power
GenerationRenewable
EnergyRenewable
EnergyEnergyServiceEnergyService
PowerTransmission
PowerTransmission
Power Distribution
Power Distribution
Industrial Application
Industrial Application
Fossil Power GenerationFossil Power
Generation
EnergySector
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.

TurboCare European Facilities
Our Customers
Locations
Our Story
TurboCare InternationalUK
TurboCare B.V.Netherlands
TurboCare S.A.Poland
TurboCare Sp. z.o.o.Poland
TurboCare S.p.A.Italy

The TurboCare Story l Customers
Utility Market Fossil Geothermal Nuclear Biomass
Industrial Market Oil & Gas Pulp & Paper Chemical Processing
Products and Services
Locations
People
Our Customers

Products and Services
Gas Turbines >
Steam Turbines >
Compressors >
Electrical Machinery >
World class capabilities in engineering, manufacturing
and service of turbomachinery with a customer first
approach for fast and reliable service.
Inspections MO / Field Service Component Repairs New Components Rerates Efficiency improvements

Privileged & Confidential Page 8
WESTINGHOUSE
W101
W191
W251 up to B8
W501 up to D5
Frame 3
Frame 5
Frame 6B
Frame 7B~EA
Frame 7FA
Frame 9EMHI
M191
M251
501F
701D
701F
GENERAL ELECTRIC
TG7
TG16
TG20
TG50 up to D5
701 DU
701F
FIAT
ABB / ALSTOM
GT11D5
GT13E2/E1
TurboCareTurboCare GT Capabilities OverviewGT Capabilities Overview

Privileged & Confidential Page 9
Steam Turbine Capabilities
ABB Stal, ACEC, Alstom, Ansaldo, BBC, Franco Tosi, Escher Wyss, Fuji, GE, LMZ,
Mitsubihi (MIH), Oerlikon, Skoda, Thermodyne, Toshiba, Zamech

TurboCare - Generators - Page 10
Generator Capabilities
Generator Services Capabilities Overview
Diagnostics Repairs Rewinds Components Balancing Upgrades Field service on generators
Sample Sample OEMOEMss:: ABB GE Mitsubishi Alsthom GEC AC Westinghouse
DOLMEL SKODA ZAMECH OERLIKON STAL ASEA Curtis Wright
GANZ ANSALDO FUJI ELIN BBC EM Brush

AgendaAgenda

Key Capabilities make the difference
Gas Turbines >
Steam Turbines >
Compressors >
Electrical Machinery >
World class capabilities in engineering, manufacturing
and service of turbomachinery with a customer first
approach for fast and reliable service.
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

Steam Turbine casing Inspections and Repairs
A
THESE DIAMETERS TO BE CONCENTRIC WITH A TO
WITHIN 0.002

2
1 Scanning positions
3
Calibration blocks
Phased Array (ultrasonic) Inspection
0
90
180
270
E DC
B
A
F

Privileged & ConfidentialTurboCare - Generators - Page 16
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

Generator Reverse Engineering
Obtaining the
geometrical model Calculations
and modeling
Dimensional
quality checks
FARO Arm
Measurement

KNOW-HOW
Highly-qualified and experiencedengineering 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 technologicalprinciples of objects throughcomputer analysis of its structure,function and operation in CADenvironment
Privileged & Confidential - Page 18
Experience
Products & Services
Company
Generator Engineering Capabilities

Reverse Engineering Process
White light Scan
Blade sample is scanned using a portable laser scanner, a white light scanner or a Coordinate Measuring Machine (CMM).
Portable CMM

Reverse Engineering
BLADE SAMPLE POINT CLOUD
3D SOLID MODELPOLYGON RENDERING

TurboCare Airfoil Engineering
DRAWING
MANUFACTURING
QUALITY CONTROL
3D SOLID MODEL
3-D Solid model spawns all downstream mfg activity.

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.
Reverse Engineering

Key Engineering Capabilities
Turbine modernizations, upgrades, and re-rates 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

Airfoil Manufacturing Facilities
Manchester, Connecticut 26,000 sq. ft. facility Staffed 24/7 ISO 9001:2000
Certified
Winston-Salem, North Carolina 305,000 sq. ft. facility Staffed 24/7 ISO 9001:2000
Certified

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 C-shaped rotor coils with a designated CIM facility.

Generator Machining Capabilities
Heavy lathes, machining to diameter 2,5 m, length to 12 m and weight to 80 tonsVertical lathes and vertical boring millsMilling and planing machines

Generator High Speed Balance facility
High Speed Balance by TurboCare
Weight of balanced rotorsbetween 5 and 80 tons
Hot balancing capability
Max rotor diameter4 meters
Max balancing rotationspeed 4.500 rpm

AgendaAgenda

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