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

PrivilegedPrivileged & Confidential Page 2

& Confidential
 Agenda

Products, Services and Organisation

What makes TurboCare a different ISP
Engineered solutions for Maintenance,
Overhauls, Repairs and Rerates

PrivilegedPrivileged & Confidential Page 3

& Confidential
 Siemens Energy Organization

Energy
Sector

FossilPower
Fossil Power Renewable
Renewable Energy
Energy Power
Power Power
Power
Oil&&Gas
Oil Gas
Generation
Generation Energy
Energy Service
Service Transmission
Transmission Distribution
Distribution

FossilPower
Power Industrial
Fossil Industrial
Generation Application
Generation 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
TurboCare B.V.
Locations Netherlands

TurboCare International
TurboCare Sp. z.o.o.
UK
Poland

TurboCare S.A.
Poland

TurboCare S.p.A.
Italy

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 The TurboCare Story l Customers

Our Customers
Utility Market
– Fossil
– Geothermal
– Nuclear
– Biomass

Industrial Market
– Oil & Gas
– Pulp & Paper
– Chemical Processing

Locations

People

Products and Services

Privileged & Confidential

 Products and Services
Gas Turbines >

Steam Turbines >

Electrical Machinery >

Compressors >

– Inspections
World class capabilities in engineering, manufacturing
– MO / Field Service
and service of turbomachinery with a “customer first” – Component Repairs
approach for fast and reliable service. – New Components
– Rerates
– Efficiency improvements

Privileged & Confidential

 TurboCare GT Capabilities Overview

GENERAL WESTINGHOUSE FIAT

ELECTRIC
Frame 3 W101 TG7

Frame 5 W191 TG16

Frame 6B W251 up to B8 TG20

W501 up to D5 TG50 up to D5
Frame 7B~EA
701 DU
Frame 7FA
MHI 701F
Frame 9E
M191
ABB / ALSTOM
M251
GT11D5
501F
GT13E2/E1
701D
701F

Privileged & Confidential Page 8

 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

 Diagnostics Sample OEM’

OEM’s:
 ABB  DOLMEL  GANZ
 Repairs
 GE  SKODA  ANSALDO
 Rewinds
 Mitsubishi  ZAMECH  FUJI
 Components  Alsthom  OERLIKON  ELIN
 Balancing  GEC  STAL  BBC
 Upgrades  AC  ASEA  EM
 Field service on generators  Westinghouse  Curtis Wright  Brush

TurboCare - Generators - Page 10

 Agenda

Products, Services and Organisation

What makes TurboCare a different ISP
Engineered solutions for Maintenance,
Overhauls, Repairs and Rerates

Privileged
Privileged & Confidential Page 11
& Confidential
 Key Capabilities make the difference
Gas Turbines >

Steam Turbines >

Electrical Machinery >

Compressors >

– Inspections
World class capabilities in engineering, manufacturing
– Reverse Engineering
and service of turbomachinery with a “customer first” – Engineering
approach for fast and reliable service. – Re-use of components
– Lead times
– Manufacturing facilities
– High Speed Balancing

Privileged & Confidential

 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”

Privileged & Confidential

 Phased Array (ultrasonic) Inspection

90 E D
C
B

180 0

270

Calibration
2 blocks
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 &
Privileged - Generators - Page 16
Confidential
 Generator Reverse Engineering

FARO Arm Obtaining the Calculations Dimensional

Measurement geometrical model and modeling quality checks

TurboCare &
Privileged - Generators - Page 17
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
Privileged Confidential- Page 18
 Reverse Engineering Process

Blade sample is scanned using a portable laser scanner,

a white light scanner or a Coordinate Measuring Machine
(CMM).

Portable CMM White light Scan

Privileged & Confidential

 Reverse Engineering

BLADE SAMPLE POINT CLOUD

POLYGON RENDERING 3D SOLID MODEL

Privileged & Confidential

 TurboCare – Airfoil Engineering

3-D Solid model spawns all downstream

mfg activity.

DRAWING

MANUFACTURING

3D SOLID MODEL

Privileged & Confidential

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

• 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
Privileged & Confidential
 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

Privileged & Confidential

 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.

TurboCare &
Privileged - Generators - Page 25
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 &
Privileged - Generators - Page 26
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 &
Privileged - Generators - Page 27
Confidential
 Agenda

Products, Services and Organisation

What makes TurboCare a different ISP
Engineered solutions for Maintenance,
Overhauls, Repairs and Rerates

Privileged
Privileged & Confidential Page 28
& 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

• 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
Privileged & Confidential
 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

Privileged & Confidential

 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)
Privileged & Confidential
 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)

Privileged & Confidential

 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)

Privileged & Confidential

 Stresses in Eroded Casing Wall

Peak Stress vs. Erosion Depth

40
35
Peak Stress - MPa

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 Macro photography of casing

washing erosion damage
Privileged & Confidential
 Baymina Project

Portable boring machine WK5 in preparation for Baymina

Project.

Privileged & Confidential

 Baymina Project

Boring machine WK5 during LP casing machining.

Privileged & Confidential

 Baymina Project

austenitic shield welds

LP casing

„Weld preparation” machining Casing view after welding

on portable boring machine

austenitic shields ( inserts )

casing

Repaired area of the casing

Penetrant NDT test after welding
after finished machining
Privileged & Confidential
 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
Privileged Confidential- Page 42
 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
Privileged Confidential- Page 43
 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
Privileged &&Confidential
Privileged Confidential- Page 44
 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
Privileged &&Confidential
Privileged Confidential- Page 45
 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
Privileged Confidential- Page 46
 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
Privileged Confidential- Page 48
 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
Privileged Confidential- Page 49
 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

Privileged &&Confidential
Privileged Confidential- Page 50
 THANK YOU !!

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