blade workshop

TurboCare is a leading aftermarket supplier of support and replacement parts for nearly all turbomachinery in operation today, including steam turbines, gas turbines, centrifugal compressors, thrust bearings, couplings, and fuel nozzles. We command the resources needed to ensure responsive design, manufacture and application of engineered component upgrades and replacements.

Introduction

Our missionTurboCare’s mission is to provide operatingimprovements to turbomachineryequipmentthrough:

• Fast, single-source response• Quality processes• Advanced technology

Industries Served

Operating a turbine at optimum efficiency and availability requires knowledgeable responsive service and support.

TurboCare’s approach to turbomachinery aftermarket support begins with understanding differing market conditions faced by today’s operators of turbomachineryin each sector:

Industrial / Process• Refining• Petrochemical• Oil and Gas• Pulp and Paper• Mining• All Others

Our active commitment to research and development produces engineered upgrades, which improve availability and efficiency of rotating equipment.From Ethylene to Ammonia, Gas, Steam or Nuclear Power Generation, wemake it our business to understand yours.

Power Generation Sectors• Geothermal• Nuclear• Fossil• Electric

Features and Benefits• TurboCare, a division of a multibillion dollar

corporation and a Fortune Global 50 company is ready, able and willing to secure your interest on this project.

• TurboCare is ISO 9001 certified, ensuring high quality engineering and company manufacturing.

• We have a proven record of meeting our delivery commitments on critical projects.

• We are the world’s leading independent aftermarket company dedicated to the repair and improvement of all makes of critical turbomachinery.

• Over 150 years cumulative engineering experience in turbine design, using state-of-art computer assisted tools, managed by the leading engineers in the industry.

• Largest engineering staff in the industry geared to aftermarket repairs to assist with decision making process for repairs during the outage.

• Single source for entire project including any engineering required.

• TurboCare will supply experienced personnel to perform all described activities and technical direction.

Engineering Capabilities

With engineered design, manufacturing and repair experience on over 40 different OEM designs of gas turbines and steam turbines, TurboCare has a proven capability to translate custom engineered designsolutions into enhanced products.

TurboCare Advantages

• Experience on over 40 different turbomachinery OEMs.• Field repair capabilities.• Over 5 million dollars in turbomachinery certified raw

material in stock inventory.

We use the latest failure analysis and design tools tocomplete work within promised delivery schedules,reducing costly downtime and repeat component failure.

Technical Resources• Turbine blades frequency testing

capabilities• Operating speed rotor balancing

bunker• Portable coordinate measuring

machines (CMM)• Airfoil failure analysis and redesign• Metallurgical evaluation• CAD/CAM expertise• Equipment retrofits• Rotor dynamic analysis• Bearing analytical capabilities

CHICOPEE OPERATIONS

Turbine Efficiency andReliability Tools

• TurboCare headquarters.• ISO 9001 certified facility.• Production floor space: 44,500 sq.ft.

(4,130 sq.m.)• 69 hourly employees.• Operation 24 hours/day, up to 7 days/week.

Components

TurboCare’s extensive inventory of turbomachinerycertified raw material ensures quick response and rapid turnaround.

Components

• Pins• Rivets• Screws• Keys• Studs• Nuts• Bolts• Washers• Bushings

• Retractable packing• Packing installation• Packing springs• Spill strips• Valve parts• ERA package• Inlet seals• Fasteners• Conventional seals• Snout rings

TurboCare Retractable Packing and Retractable Brush Seals

Our Retractable Packing and Retractable Brush Seals are among the most significantdevelopments in turbomachinery efficiencyImprovements for steam turbines available.The U.S. Department of Energy (DOE) hasrecognized retractable packing for itscontributions to energy savings, estimatingthe cumulative effect of retractable packingFrom introduction through 1997 translatesto a fuel savings equivalent of some 52.13trillion Btu.

MANCHESTER OPERATIONS

Turbine Blade Facility

l Approximately 26,000 sq. ft. (2,400 m²).l ISO 9001 certified facility.l 83 full time employees.l 3 shifts - 24 hour coverage - Normally 5

days a week operation, 7 days a week during outage season.

l Full blade manufacturing capabilities.l Over US$ 2 million in high quality blade

specific materials in stock.l Over 30 years of blade manufacturing

experience.

AIRFOILS: Design to Installation

For three decades TurboCare has been the leader in alternative manufacture of steam turbine blades for virtually every design of turbomachinery

Design to Installation

• Rerates and redesign.• Material upgrades.• Rapid turnaround.• Efficiency and reliability improvements.• State-of-the-art manufacturing facility.• Experience with all OEMs.• Alternative erosion protection.• Blade installation.• Banding.• Machining.• On-site or OpSpeed Balance.

Typical Steam Turbine Blade Manufacturing

As received

Days later, a full set including hardware

Steam Turbine Blade Manufacturing

l Fast lead time jobs start with bar stock.

l We stock millions of dollars of stock of various alloys and sizes.

l Most common alloys are stocked in bulk form.

Ø 305,000 square feet of blade manufacturing.Ø Four and five axis machiningØ Diaphragm and nozzle blocks.Ø Compressor BladesØ Capable of producing over 24,000 blade styles.Ø Large forged blade capabilities.Ø 6 Shifts – 24 Hour coverage, 7 days a weekØ On-time DeliveriesØ ISO 9001 Certified

Winston Salem, NC

Steam Turbine Blade Manufacturing

l Fast lead time jobs start with bar stock

l We stock Millions of dollars of stock of various alloys and sizes.

l Most common alloys are stocked in bulk form.

Steam Turbine Blade Manufacturing

l In addition to bar stock, frequently TurboCare uses composite or envelope forgings.

l We own a large quantity of forging dies and frequently stock raw forgings for quick delivery.

Steam Turbine Blade Manufacturing

l Most parts are machined using CNC multi axis milling centers.

l In addition TurboCare frequently utilize Wire EDM equipment and other custom made airfoil Machines.

The opening of TurboCare’s East Hartford Facility expands TurboCare’s dedication to serving the needs of the gas turbine users. Developments in turbine blades redesign, turbine repair, turbine rotor repair, and gas turbine brush seals are further testament tothe skill and commitment of TurboCare’steam of experienced engineers.

TurboCare East Hartford, CT

Gas Turbine Facility

• 14,000 sq.ft. (4,250 m²).• Report to Airfoil GM.• Independent staff.• 30+ employees.• Operational on July 2000.

Modern Machine Tool Capabilities

CapabilitiesTurboCare is committed to providing operators of gas turbines with a complete range of manufacturing and repair options including:

• Open and close services.• Efficiency improvements.• Component manufacturing and repairs.• Component replacement – Replica or advance design.• Turbine spares.• Turbine parts.

Gas Turbine Products• Gas turbine blades and buckets.• Compressor blades and vanes.• Inlet guide vanes.• Shroud blocks.• Turbine spares.• Brush seals.

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Gas Turbine Coatings

Services• Turbine blades failure analysis

and redesign for reliability• Reverse engineering• Finite element stress and heat

transfer analysis• Thermodynamic performance

evaluation• Rotor dynamic analysis, high

speed balance and bearing design• Rotating equipment overhaul• Technical field assistance• STEAM evaluations• Advanced weld repair technology• Mechanical and aerodynamic design

technology

HOUSTON OPERATIONS

Open and close turbine overhaul facility

• New facility operational since July 2001.

• ISO 9001 certified.• 139,000 sq.ft (12,914 m²).• Independent staff.

Designed to be an efficient Turbomachinery Repair Facility

h 100 Ton Crane 39 Ft Hook

h 125,000 sq. Foot Facility

h 60 Foot High Bay

Rotating and Stationary Repair• Rotor diagnostic analysis.• Failure analysis and non-destructive testing.• STEAM Evaluation for turbines.• Advanced rotor and shaft submerged arc welding.• Repairs for axial and centrifugal compressors.• Repair of turbine blades, buckets and vanes.• Operating speed and low speed balance.• Diaphragm, nozzle and casing repairs.• Stationary turbine blades manufacture & repair.• Joint hardware and fasteners.• Custom designed and field fit labyrinth seals.• Labyrinth seal holder modification.• Efficiency and Reliability Advantage (ERA) Upgrades.• Complete valve overhaul capabilities.• Gas turbines components repair.

Field Services

TurboCare field services delivershighly trained technicians and fieldengineering support services toreduce the demands placed on plantresources and personnel during outages.

Equipped with a fleet of mobile CNC work centers andbacked-up by a full team of experienced engineers, TurboCareField service technicians are available 24 hours a day, anywherein the world.

Main Unit Valve Overhauls

lInspectionslReplacement PartslRebuildslControlslAssembly

On-Site Rotor Machining

l Portable lathe

l Low speed balance

l Shaft & band machining

Shell/Casing Repair & Machining

l Horizontal Joint Repairsl Stationary Blade Repairsl Inlet Area Repairsl Flange Machiningl Re-Roundingl Repair and machining of

Diaphragm Grooves

Operating Speed Balance Bunker

Quality Control

CapabilityCapability uu InnovationInnovation uuFlexibilityFlexibility

Offering Engineered Solutions & Short Cycle Times