ARNOLD Group

Arnold Group Maintenance solution for Siemens VX4.3A Gas Turbines

Arnold Group Maintenance solution for Siemens VX4.2 Gas Turbines

ARNOLD Company Profile Headquarter Filderstadt (Germany)

Eugen Arnold GmbH was founded 1949 in Filderstadt (Germany)

Global network of local offices and workshops We occupy around 345 employees worldwide Our field of activities mainly includes:

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Mechanical Siemens Gas Turbine Maintenance

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Mobile On Site Machining Services

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High Quality Turbine Insulation Systems

A small abstract of our references: •

Westinghouse Electric

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General Electric

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Alstom Power

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Shanghai Turbine Company

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Mitsubishi

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Power Machines Russia

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Siemens AG

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Voith Turbo GmbH & Co KG

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ABB

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Daimler AG

Wujiang (China)

Sisov (Slowakia)

ARNOLD Quality Standard Our Quality Demand On behalf of our customers, the quality standards of our work are extremely demanding on which we keep aligning our actions to provide every day: - Perfect Customer Focus - Custom-made performances for the needs and preferences of our customers - Usage of aggregated experiences and synergies - Continuous improvement of the production and project management If you have any questions, please feel free to contact our Quality Manager : Mr. Michael Sander: [email protected] +49 / 7158 / 9014 - 437

BS OHSAS 18001:2007

SCC

ISO 9001:2008

Why Non-OEM Service is necessary: • Flexibility worldwide, due to flat hierarchies and team work character of our medium size company + local partner for local workscope • ARNOLD Quality Standard and continuous improvement cycle • Reliability: We keep our promises! • BEST Price Guarantee • Work Attitude: Nothing is impossible! • Motivated and skilled outage team Æ Plus, ARNOLD offer 24h Supervisor Service worldwide

ARNOLD Performance Overview

ARNOLD Additional Values • Minor Standard Inspection within 4-5 days • HGPI of approximately 22 days • Major Overhaul of approximately 28 days • Lifetime Extension of approximately 35 days

Æ Additional extended output possible (MW)

ARNOLD Project Structure ARNOLD Group Main Contractor

Störung

SIPA Powertech

ARNOLD Field Service Division

Project Execution Risk & Project Management

Project Execution Risk & Project Management

- Outage Management - Commissioning - I&C Commissioning

- Outage Management - Field Service Activities - Field Service Specialist

Arnold (Germany) Arnold (Germany) - Erection - Tools - Welders - Fitters - Combustion Chamber Specialists - Blade fitters

- Admin Management - HSE - Insulation - Field Service Work scope - On-Site Repair works

Backup Engineering(Germany) - Engineering - Reengineering - Life time assessment - Life time extension - Delivery of workshop drawings - QS manufacturing process - Expediting

Different Spare Part Suppliers - Turbine components manufacturing - Parts Refurbishment - Repair Shop

ARNOLD Project Structure ARNOLD Group ARNOLD Field Service – SIPA

Field Service Team

site administration safety manager Site Infrastructure Visual inspection Turbine de- and reassembling store management fork lift, crane driver turbine components Clearing / measurement protocol

insulation noise enclosure burner washing electrical welding storage piping Inspection Shift leader Combustion Glas pearl blasting Dry ice blasting

On Site Machining

Backup Engineering

grinding Drilling line boring cutting milling turning blade grinding rotor machining joint machining Nabe + Hub repair Burner repair reporting

Fact finding Material Analysis Engineering Design, Analysis Repair Solutions Life time Assessment Quality Insurance

ARNOLD On Site Service Team SIPA On Site Service Team

SIPA

Project

Management Site Management Fact finding I&C Maintenance Commissioning Engineering Reporting Risk Analysis Vibration Measurement

NDT

Ultra Sonic Test Magnetic Test Dye penetrant Test Eddy Current Test Visual Test Analysis and Report

Organizing the working and lay down areas for the overhaul Layout of the overhaul situation within the power plant

Dismounting of a VX4.3A Gas Turbine Disassembling , measurements and fact finding



Dismounting of a V.X4.3A Gas Turbine Disassembling , measurements and fact finding

Dismounting of a VX4.3A Gas Turbine Disassembling of the rotor

Working out repairs solution for VX4.3A Gas Turbine Repairwork

Service Work at the combustion chamber of a VX4.3A Fact finding and replacement of ceramic tiles inside the combustion chamber

Working out repairs solution for VX4.3A Gas Turbine

Reconditioning of the Diffusor Repair procedures have to be evaluated according to fact finding results

Mechanical work scope at Gas Turbines with annular combustion chamber

Blade grinding

Grinding-, lathing-, and milling works on the diffuser.

Flangemachining

Cooling air hole drilling

Blade grinding

Shaft machining

Shaft machining Installing of accelerometers

Joint machining

Mechanical work scope at Gas Turbines with silo combustion chamber Drilling out of Bolts,Tapping Blade grinding

Shaft machining

x

x Flange machining

Installing of accelerometers

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t

t

Shaft machining

Joint machining

Service Work at a VX4.3A Gas Turbine Installation of Spare Parts Repairing and Modifications Repair work and Modification on Site for all turbine equipment

Service Work at the rotor of a VX4.3A Gas Turbine Change of Turbine blades Repair of the Casing Repair work on Site for nearly all turbine equipment

Service Work at a VX4.XX Gas Turbine Installation of Spare Parts Repairing and Modifications Repair work and Modification on Site for all turbine equipment

Service Work at a VX4.3A Gas Turbine Installation of Spare Parts Repairing and Modifications Repair work and Modification on Site for all turbine equipment

Service at the oil and gas skids of the VX4.XX Gas Turbine

De- and reassembling of Pumps and valves. Overhaul and change of the spare parts

Working out repairs solution for VX4.2 GasTurbine

Sample of a Mixing Chamber repair Fact finding of the Mixing Chambers during inspection

Repair:

Grinding and welding repair

Working out repairs solution for VX4.2 GasTurbine

Sample of a Mixing Chamber repair Repair procedure must be evaluate according to fact finding

Repair:

Renew the cooling air rings and preparing the dimensioning inclusive heat treatment on site

Service Work on the mixing chamber of the VX4.2 Gas Heat treatment on site after welding and repair of the mixing chamber

Service Work on the rotor of the VX4.2 Gas Turbine Change of Turbine blades Repair of the Inner Casing Repairwork on Site for all turbine equipment

VX4.2 Inner Casing VX4.2 Inner Casing Problems

VX4.2 Inner Casing Solutions

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Inner barrel cracking

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Finite element analysis

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Fretting of radiation liner spacer disks

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Flange relocation and redesign

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Inlet fretting from elbow transition rings

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Cooling air bypass

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Cracking near inlet bowl

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Inner barrel with upgraded material, forged flange

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Cracking at radiation liner pins

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Thermal barrier coating

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Centering pin boss fretting

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Chrome carbide coating

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Casing/inlet bowl finger wear

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New radiation liner spacer disks, upgraded material

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K-ring wear

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Spacer disks welded to radiation liner pins

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1st stage vane seal ring wear

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New seal rings from upgraded material

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Radiation liner modification

Dismounting of the Gas Turbine VX4.2 Disassembling , measurements and fact finding

Dismounting of the Gas Turbine VX4.2 Disassembling of the rotor

Working out repairs solution for VX4.2 + VX4.3A GasTurbine

Sample of a Hub Restoration Repair procedure must be evaluate according to fact finding

Option A: Risk evaluation for further 25.000 EOH´s intervall including machining of the detected hub nose and installation of new set of tiles with big nose at row 1. Machining on stacked rotor is possible. Option B: Destacking the rotor and repair the hub in the work shop with grinding out the crack defected area, install new repair part with welding and heat treatment and finishing with machining to the original dimension

Cleaning solution for Siemens Gas Turbines Condition of Premix burner befor cleaning

Cleaning solution for Siemens Gas Turbines burners Condition of Premix burner after cleaning

Cleaning solution for Siemens Gas Turbines burners Comparison before and after Cleaning of VX4.2 Burners

Burner Cleaning Solution on site Onsite Cleaning solutions for GT parts

For example Burner Washing with Flow Measurement

Service Work on the V.X4.XX Gas Turbine Blasting of turbine parts

Logistic of the Repairwork for all parts and turbine equipment

Spare Parts - Capital Parts ARNOLD can supply turn-key: – Supply of inlet guide vanes (IGV’s) – Supply of compressor blades and stator vanes – Supply of combustor dome plates, burner bezel rings – Supply of combustor bricks – Supply of inner casings and mixing chambers – Supply and/or technical/commercial assistance in establishing a turbine blade/vane manufacturing program • Engineering Services – Development of Component Definition – Manufacturing Process Development – Engineered upgrades Better materials Design modifications Coating additions •

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Casting Machining Coating – Engineered Upgrades! – Vendor Oversight – adherence to fixed processes – QA/QC

Spare Parts - Capital Parts

Spare Parts - Consumable Parts • •

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All Vx4. Consumable Parts! Combustor Hardware – bricks, tile clips, assembly hardware Turbine vane segmented seals, vane seals and assembly parts Blade locking plates, pins IGV Hardware – bushings, washers, etc. Oil Burners Supply of B3/B5/B8 list consumables Significant orders previously filled (> 1200 different line items) Can scan existing Spare Parts Manuals to Adobe (.pdf) files and provide cross- reference to our part numbers Significant economic advantage!

Spare Parts - Consumable Parts

Spare Parts - Consumable Parts

Special Experience Inlet Guide Vanes •

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All assembly hardware – bushings, washers, lock screws, seals, etc. New shafts Repair of worn shafts Ring rack assembly hardware – bearings, rod ends, etc. IGV re-coating

Compressor Section • •

Compressor Coatings Diaphragm Repairs

Combustor Parts • • • • • • • • •

Burner Oil Return Line Burner Caps Fuel Oil Nozzle Oil Burner Overhaul & Flow Testing Combination Burner Overhaul Replaceable Flashback Thermocouples Burner Insert Ring Repair and Coating New Burner Insert Rings Cast from IN738 Burner Insert upgrade with TBC and CrC Coating

Combustor Parts Swirler Repair Distributor Repair &Coating New Vanes Blades & Vanes Coating Tile clips • Upgrade material • Add thermal barrier coatings • Tile Holder • Mounting Pins • Socket Cap Screws • Ceramic Bricks (Tighter Dimensional Control than Norton Bricks Eliminates Stack-up Problems!) Tile Support Ring • New rings manufactured from same or upgraded material – Hastelloy X • New rings manufactured in segments for ease of installation • • • • •

Special Experience Combustor Parts

Inner Casings

“Star” and Segment Plates • Repair and Coating • New Manufacture – IN617 or Haynes • TBC Coating • CrC Coating • Refurbishment and Replacement Options! • New Plates Manufactured From IN617 or Haynes 230 • Optional Coating with Thermal Barrier Coating (TBC) • Optional Wear Resistant Coatings to Eliminate Fretting Damage

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Mixing Casings (Elbows) • • • • •

Repair Cooling Air Transition Ring TBC in high-heat areas CrC on transition ring OD NEW Manufacture

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Repair Upgrades New Casing Manufacture! Reverse engineering of entire inner casing and all detail parts completed Definition of all components with manufacturing drawings Offering new casing from In617 or Haynes 230 material

Turbine Vanes • • • • • •

Disassembly and Inspection Weld and Braze Repairs Coating Upgrades Seal Slot Mods Assembly Hardware Check Fit Fixtures

Turbine Blades • • •

Masking and Stripping – Pt Core Pins Weld Repairs Coating Upgrades

Special Experience For every outage you need special tools for the movement of the parts and the repair

Special Tooling

Special Tooling

Commissioning Execution Arnold and SIPA COMMISSIONING PROCESS* Records of shut down parameters - control and protection signals - Vibration measurements incl. Mobile (reference values by load and nominal speed ) - control behavior of valves - Leakage detections

Records during cold commissioning - testing of all control and protections systems( compressor, burning chamber, turbine, gas system, hydraulic control system - dynamic simulation test of control and protection systems

Records during hot commissioning - control and protection signals - Vibration measurements incl. Mobile (reference values by load and nominal speed ) - control behavior of valves - Leakage detections

*Supporting of I&C process engineer

Fact Finding and Backup Engineering for Turbine Parts Design, Analysis, Processes Turbine/ engine systems and parts

Thermal Steady-state analysis

Transient analysis (start-up, shut-down) Conjugate heat transfer Thermodynamics Heat circuit balance Differential expansion

Structural Mechanics

Fatigue

Structural Dynamics

Linear-elastic Analysis Non-linear Analysis

Rotor dynamics (turbo train)

Inelastic Material Behaviour

Blade-rotor dynamics

Viscoplasticity

Blade-disc dynamics

Creep deformation

Bearing dynamics (EHD)

TMF

Multi-body dynamics

Fracture mechanics

Contact Mechanics Limit and shakedown analysis (LISA) Optimisation Topology and shape and multidisciplinary parameter optimisation Seismic analysis

HCF safe-life with multiaxiality LCF strain life Fretting fatigue Creep rupture Creep-fatigue interaction Probabilistic fracture mechanics Probabilistic life assessment ASME / API / EN 13445Codes R5-Procedure

Quality

CFD Uncoupled heat transfer

Engineering process analysis & Redesign

Conjugate heat transfer

Manufacturing process analysis & Redesign

Casings Blade assemblies Diaphragms

FMEA

Aerodynamics

Quality management Supplier qualification Inspection programs I&T plans

Working instructions

Quality inspection Expediting

Fact Finding and Engineering for Turbine components

Thermal & Performance Engineering

Targets: • •

Increase Plant Efficiency Increase Part Life Time

Measures: • • • • • •

Pre & Post Outage Performance Analyses Plant parameter updates according operation conditions Basis for plant performance is acceptance test after first commissioning Heat rate analysis Updates for efficiency increase Life time extension programs

Maintenance Reference

Major Overhaul at a SGT5 4000F Gas Turbine Result: • Load increase of 18,4 MW • Efficiency increase of 0,6% This extraordinary performance and efficiency increasing was a result of advanced Gas Turbine Maintenance knowledge of ARNOLD & SIPA.

ARNOLD Field Service Activities Reference List

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Palos de la Frontera (Spain)

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Jebel Ali G (UAE)

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Arubal (Spain)

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Al Aweer (UAE)

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Campo de Gibraltar (Spain)

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Rudeshur (Iran)

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Sagunto (Spain)

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Ludwigshafen (Germany)

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Piacenza (Italy)

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Mirfa (UAE)

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Porto Maghera (Italy)

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Sohar (Oman)

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Livorno (Italy)

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St. Petersburg NW (Russia)

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Ribatejo (Portugal)

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Al Ezzel (Bahrain)

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Tapada (Portugal)

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Chana 1&2 (Thailand)

Thank you for your kind attention Please feel free to contact me at any time if you have any question!

My personal contact details are: Phone: Fax: Mobil: Email:

+49 7158 / 90 14 0 +49 7158 / 90 14 612 +49 172 / 62 45 980 [email protected]

Homepage: www.arnoldgroup.com

Werner Arnold General Manager

Thank you for your kind attention I hope I could arouse your interests with this little presentation. Please don´t hesitate to contact me if you have any further question. My personal contact details are: Phone: Fax: Mobil: Email:

+49 7158 / 90 14 462 +49 7158 / 90 14 662 +49 176 10 28 65 33 [email protected]

Homepage: www.arnoldgroup.com

Pierre Ansmann Global Head of Marketing