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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
Privileged & ConfidentialPrivileged & Confidential Page 3
AgendaAgenda
Products, Services and Products, Services and OrganisationOrganisation
What makes What makes TurboCareTurboCare a different ISPa different ISP
Engineered solutions for Maintenance, Engineered solutions for Maintenance,
Overhauls, Repairs and ReratesOverhauls, Repairs and Rerates
Privileged & Confidential
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.
Privileged & Confidential
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
Privileged & Confidential
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
Privileged & Confidential
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
Privileged & ConfidentialPrivileged & Confidential Page 11
AgendaAgenda
Products, Services and Products, Services and OrganisationOrganisation
What makes What makes TurboCareTurboCare a different ISPa different ISP
Engineered solutions for Maintenance, Engineered solutions for Maintenance,
Overhauls, Repairs and ReratesOverhauls, Repairs and Rerates
Privileged & Confidential
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
Privileged & Confidential
Steam Turbine casing Inspections and Repairs
Non-contact areas
Example of blue check results
Privileged & Confidential
Steam Turbine casing Inspections and Repairs
A
THESE DIAMETERS TO BE CONCENTRIC WITH A TO
WITHIN 0.002
Privileged & Confidential
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
Privileged & ConfidentialTurboCare - Generators - Page 17
Generator Reverse Engineering
Obtaining the
geometrical model Calculations
and modeling
Dimensional
quality checks
FARO Arm
Measurement
Privileged & Confidential
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
Privileged & Confidential
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
Privileged & Confidential
Reverse Engineering
BLADE SAMPLE POINT CLOUD
3D SOLID MODELPOLYGON RENDERING
Privileged & Confidential
TurboCare Airfoil Engineering
DRAWING
MANUFACTURING
QUALITY CONTROL
3D SOLID MODEL
3-D Solid model spawns all downstream mfg activity.
Privileged & Confidential
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
Privileged & Confidential
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
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
Privileged & ConfidentialTurboCare - Generators - Page 25
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.
Privileged & ConfidentialTurboCare - Generators - Page 26
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
Privileged & ConfidentialTurboCare - Generators - Page 27
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
Privileged & ConfidentialPrivileged & Confidential Page 28
AgendaAgenda
Products, Services and Products, Services and OrganisationOrganisation
What makes What makes TurboCareTurboCare a different ISPa different ISP
Engineered solutions for Maintenance, Engineered solutions for Maintenance,
Overhauls, Repairs and ReratesOverhauls, Repairs and Rerates
Privileged & Confidential
Baymin