Sulzer Turbo Services

Transcription

1 Sulzer Turbo Services

2 Start-Up Services Sulzer Turbo Services Worldwide repair and testing facilities Continuous Training Field Service Engineering LTSA s Our largest facility, located in La Porte, TX near Houston Repair Shop Services Balancing Coating Manufacturing Facility Map - Houston, TX Area Location 1 Combustion Parts Repair 2 Components Engineering / Metallurgical Lab 3 Component Repair 4 Air and Thermal Spray Coatings 5 Blade / Impeller Manufacturing 6 Parts Inventory 7 Rotor Storage 8 Shipping / Receiving 9 Core Shop Machining & Grinding 10 Core Shop Welding 11 Core Shop Inspection / Balancing 12 Core Shop Assembly Bay 13 Administration / Sales / Engineering 14 Big Bay Large Rotor Repair / Balancing 15 Administration Reception 16 At-Speed Balance 17 Cleaning Facility/Plant Maintenance 18 Big Bay II Large Unit Assembly 19 NDT / Steam Cleaning / Quality / Environmental / Health / Safety / ISO Offices 20 Field Services 21 Purchasing

3 World Class Personnel Sulzer Turbo Services is a network of worldwide locations. Our rapid growth is a result of our commitment to become the world leader in third party repair services. Our largest facility is located in La Porte, Texas, just east of Houston. Now, with service locations in the US, Canada, Europe, Indonesia and South America we have become a global force in the repair of critical rotating equipment. Sulzer Turbo Services has provided customers with high quality services at competitive prices, and delivery times that are often shorter than those of the OEM s. Sulzer Turbo Services is a global force in rotating equipment repair. By sharing resources, technology and values, we offer superior results, unmatched responsiveness and the greatest versatility to our customers. Sulzer Turbo Services utilizes the latest engineering programs such as Ansys, XL Rotor, Unigraphics, Autocad and others to perform complete engineering analysis. A full engineering staff is involved in all phases of repairs, redesigns, and re-rates. Finite element analysis, rotor dynamic analysis, and design upgrades are just a few of the services offered. With the technical expertise to enhance and improve an existing design, Sulzer Turbo Services stands alone in putting our vision and capabilities to work in solving our customers problems. Our services are available 24 hours per day, seven days per week. 1

4 Field Service Downsizing at many plants has created an increasing demand for out-sourced turbomachinery maintenance and technical expertise. At Sulzer Turbo Services, we have the experienced personnel and the tooling to assist with all our customers field service requirements. The Sulzer Turbo Services Field Service Division provides timely and efficient on-site maintenance and repair services for our customers worldwide. Our dedicated staff of technical directors, diagnostics engineers, supervisors and skilled technicians can provide total plant outage maintenance, complete machinery turnaround staffing, emergency call out services, on-site troubleshooting and analysis; as well as the immediate removal, off-site repair and reinstallation of the equipment. In addition, we have invested in the latest technology, including ADRE III for Windows analysis programs and laser/optical alignment and measuring tools to complement the conventional items contained in our fully stocked mobile field equipment and nondestructive testing trailers. Crews come to your site ready and equipped to work for you. 2

5 Engineering Services Sulzer Turbo Services has a staff of degreed and professional engineers involved in all aspects of production, manufacturing, coating and repair. Project Managers are assigned to oversee all phases of equipment repair from inspection to completion of all major projects. Capable of designing, re-rating, improving critical equipment, and led by some of the world s most respected turbomachinery analysts, Sulzer Turbo Services engineering department can offer you the following services: Re-rates Lateral and torsional rotordynamic studies Modal impact analysis Root cause failure analysis In-house x-ray capabilities Bearing designs and modifications Unique solutions to complex problems Vibration analysis and on-site trouble-shooting 3

6 Rotating Equipment Repair Sulzer Turbo Services repairs, refurbishes, re-engineers, manufactures and balances: centrifugal, axial and process dry screw compressors, steam and gas turbines, expanders and other components such as speed increasers/reducers and other complementary items. Routine rotating equipment overhaul consists of: Gas Turbine Rotors and Thermal Blocks Gas and Steam Turbine Components 4 Inspection and disassembly, non- destructive testing, repair/ refurbishment or replacement of worn parts, coating of component parts, re-assembly, balancing at low and full operational speed, CAD documentation packages of all completed work. Sulzer Turbo Services is the world s leading resource for the turnkey repair and restoration of industrial and utility gas turbines. Our repair processes are specifically customized to solve wear and tear problems and strengthen weaknesses encountered in the conventional operation of modern gas turbines. Specializing in F-Class technology repairs and coatings, Sulzer Turbo Services features a fully equipped metallurgical laboratory, including scanning electron microscope (SEM) for component life evaluations, digital x-ray for examining turbine blade internal microstructure, vacuum heat treat furnaces, plunge precision EDM, robotic coating, CMM, stem drilling and CAD documentation for all reports.

7 Rotating Equipment Repair Sulzer Turbo Services also repairs and remanufactures complete replacement rotating and stationary assemblies for steam turbines and centrifugal compressors of all sizes, makes and models, including turbine reblading and rehabilitation of rotor components. Compressors Expanders Steam Turbines We are capable of full turnkey disassembly, inspection, repair, and component part manufacturing of centrifugal, axial, and screw compressors. With shops located around the world, and rotor storage, we are ready to handle all of your routine and emergency repairs. Sulzer Turbo Services offers complete in-house coating and grinding capabilities, which allows control of emergency schedules. Sulzer Turbo Services is one of only a few aftermarket repair companies with the experienced engineering expertise to perform repairs to these complex machines. Virtually every component of an expander can be manufactured or repaired by Sulzer Turbo Services. Our engineers are involved in every phase of the repair, providing upgraded designs for reliability and extended life of components, including manufacture of complete rotor assemblies. Our experience covers all manufacturers, makes, and models of steam turbines. Complete rotors, diaphragms, and other components are routinely manufactured in our facilities. We also offer upgrades, re-rates, and redesigns on many components. New steam turbine blading is manufactured by Sulzer Turbo Services in our state-ofthe-art blade manufacturing facilities. 5

8 Manufacturing Manufacturing combines the ultra-precise functions of coordinate measuring machines (CMM), computer-aided numerically controlled (CNC) machining and computer-aided design and drafting (CADD) tools to produce replacement compressor impellers, axial compressor and steam turbine rotating and stationary blades. Sulzer Turbo Services has successfully integrated these technologies with other innovative and advanced processes such as gold-nickel brazing to produce superior impellers that exceed industry standards for quality, performance and delivery. State-of-the-art 5 axis CNC mills, tool post grinders and 3-D software allow us to produce virtually any type of blade with a variety of root forms and tenons. Sulzer Turbo Services performs failure analysis and evaluations including fracture mechanics, stress and fatigue testing, short-term loading, frequency testing, and finite element modeling to support blade and foil redesign if needed. 6

9 Technical Services Sulzer Turbo Services has many years of field experience in collecting data and analyzing machinery problems such as high vibration and reduced performance. Sulzer Turbo Services engineering staff uses the gathered information to make recommendations for upgrades, design changes, or appropriate repairs to maximize the operation of our customers equipment. We carefully and completely evaluate the condition of your machinery and offer solutions based on experience and sound engineering judgement. Examples of the problems we routinely resolve are: Excessive Vibration Misalignment Coupling, Bearing & Seal Problems Machinery Protection Systems Unbalance Training and Support 7

10 Protective Coatings The HICoat Division provides protective coatings to enhance equipment performance and longevity through resistance to corrosion, wear and heat. Air Spray - Available in a wide range of thicknesses and top coats, this technique delivers superior corrosion resistance, improved aerodynamic efficiency, longer equipment life and improved performance. Typical applications: compressor and stator blades of gas turbines, gas compressor impellers, and diffusers, steam turbine rotors, blades and diaphragms. Plasma - This highly versatile thermal barrier coating technique yields high bond strengths of 2,500 to 10,000 psi. It also provides high heat protection which slows thermal fatigue and stress damage in hot section components such as: combustion liners, cowl caps, transition pieces, turbine nozzles/vane segments and turbine blades. HP-HVOF (High Pressure-High Velocity Oxygen Fuel) This robotic coating technique delivers high particle velocities and low flame dwell time yielding extremely high bond strengths of 7,500 to 10,000 psi, high coating density of less than 1.5% porosity and exceptional protection against oxidation, corrosion, abrasion, erosion, fretting and slide wear in turbine blades, buckets, nozzles and vane segments. 8

11 At-Speed Rotor Balancing Sulzer Turbo Services At-Speed rotor balancing service features a vacuum balancing bunker in which rotors can be balanced at full operational speed. This eliminates the need for field balancing which can be costly and time consuming. Equipment will run at lower vibration levels, which help maintain the reliability of the equipment. At-Speed rotor balancing is performed at our Houston area location. The At-Speed Rotor Balancing bunker features: 98 in. (250 cm.) outer diameter rotor capacity 280 in. (853 cm.) length rotor capacity Oversize vacuum pumps, capable of evacuating the bunker in less than ten minutes Nyquist/Bode plotting with ADRE III or with Windows capability Up to 16 channels to monitor data acquisition for rotor velocity, force and displacement Flux probe testing of generator rotors at full speed Generator rotor coil seasoning The bunker accommodates rotors up to 50,000 lbs (22,680 kg.) and can balance rotors at speeds up to 40,000 rpm. 9

12 Americas Sulzer Turbo Services Houston Inc Old LaPorte Road TX USA Phone: Fax: Europe, Middle East, Asia Sulzer Turbo Services Venlo BV Spikweien 36 NL-5943 AD Lomm The Netherlands Phone: Fax: Asia Pacific Sulzer Turbo Services Asia 10 Bentor Sector Singapore Phone: United Kingdom Sulzer Dowding & Mills Camp Hill Birmingham B12 0JJ United Kingdom Phone: Fax: Geographic main office and 26 facillities Geographic main offices Facillities