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PT. ALBANY ENGINEERING SERVICES
JL. RAYA PANYAWUNGAN KM.0,8TELP. : (022) 7796455 (HUNTING), 7796466, FAX. : (022) 7796678, 2013734
WEBSITE : www.albanybandung.com
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PT. ALBANY ENGINEERING SEVICESPT. ALBANY ENGINEERING SEVICES
Found : 29 November 2008, Formerly named PT. Albany Yasa Utama, Found : 18 February 1993
Land : 4,000 sqm, Shop Floor and Offices : 3,000 sqm
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1. To Provide Support For Full
Service Capability
2. Become The Customers Natural
MISSION & APPLICATION
• GE :Frames 3, 5, 6, 7 and 9
• Westinghouse : W191, W251,
W501.
MISSION APPLICATION
~ Quality
~ Cost
~ Delivery
3. To be the Repair Service Centre Of
Excellence in Indonesia.
• Mitsubishi : MW 701 D.
• ABB : Types 13 E
• Siemens : V94
• Various Steam Turbine Rotor,
Compressor, Pumps, etc
3
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NORMALLY INSPECTION & REPAIR INTERVAL
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CERTIFIED MAN POWER REQUITED
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• REPAIR OF ROTATING EQUIPMENT SERVICES- Gas Turbine
– Centrifugal Compressor
– Single & Multi Stage Pump
– Steam Turbine
– Turbo Charger
– Hydro
– Reciprocating
• REPAIR OF HEAVY DUTY GAS TURBINE COMPONENT – Gas Turbine Bucket
– Gas Turbine Cold section ( Compressor ) Blades
– Turbine Power Nozzle / Vane Segment
– Transition Pieces.
– Combustion Liners / Combustion Basket.
– Shroud Blocks.
– Fuel Nozzles.
– Compressor Stator.
BUSINESS FOCUSBUSINESS FOCUS
– Bul Horn.
– Diaphragm.
– Support Ring.
– Bearings.
– Burner.
Screw Compressor Rotor TP after Repair6
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BASIC SERVICE TECHNOLOGY
ENGINEERING PROCESS &
SPECIFICATION
Function of its components.
Operating condition : Temperature,
Pressure, Speed, Control Device, etc.
Check the original material and
GT29/33 COATING by HVOF
manufacturing process.
Check the original dimension.
Provide Tailor Made Work Order
(TMWO) / Repair Sequence.
Provide Repairable Criteria.
Material Characteristics
GT33-CoNiCrAlY vs GT29-CoCrAlY
• Much better oxidation resistance than
GT29
• Higher craze crack resistance
compared to GT299
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DIAPHRAGM SEAL
•Full NDT Inspection
•Weld build up or satellite coating
•Replace all knife seal
•Machine to the original
drawing dimension
MAJOR EQUIPMENT &
MAJOR REPAIR PROCESS ( CONT’D )
Shrouds After Repair
•Assembly with Special fixture
Shroud Block Fixture for Machining to Dimension
11
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MAJOR EQUIPMENT & MAJOR REPAIR PROCESSMAJOR EQUIPMENT & MAJOR REPAIR PROCESS
NOZZLE REPAIR
o Coupon manufacture
o Trailing edge coupon restoration
o EDM machining
o Downstream Deflection correction
o Fixture repaired components Nozzle segment before Repair
o Hydrogen bright annealing
o Solution age run
Nozzle segment after Repair
12
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BUCKET AND BLADES
•Cleaning
•Stripping
•Tip build ups
•Angel wing restoration
•Moment weighs
•
NDT
MAJOR REPAIR PROCESS ( CONT’D )
•Coatings
•Stellite inlay
REPAIR PROCESS ( BLENDING ) BUCKET AFTER REPAIR
Ultrasonic Test to Insures minimum wall thickness
requirements are met
13
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MAJOR EQUIPMENT & MAJOR REPAIR PROCESSMAJOR EQUIPMENT & MAJOR REPAIR PROCESS
NOZZLE REPAIR
o Coupon manufacture
o Trailing edge coupon restoration
o EDM machining
o Downstream Deflection correction
o Fixture repaired components Nozzle segment before Repair
o Hydrogen bright annealing
o Solution age run
Nozzle segment after Repair
14
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GAS TURBINE PART REPAIRGAS TURBINE PART REPAIR
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Repair on first Stage bucket Airfoil of MS 9001ERepair on first Stage bucket Airfoil of MS 9001E
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ROTOR REPAIR
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ROTOR
Repair Work scope
JOB NO. : DRAWING NO. :
CUSTOMER : Pupuk Kaltim SERIAL NO. :DESCRIPTION : Turbine Wheel GT-1005-B QUANTITY : 1 SET
1 Perform receiving inspection, Photograph as received condition
2 Blast Clean turbine wheel with Aloxs
3 NDT & Mapping all Defect as required
4 Visual Inspection
5 Provide Incoming Inspection Report
6 Remove old shroud and blades 1st and 2nd stage and stationary blades
7 Dimensional check on T-Slot or Groove and NDT
8 Fabricate new Blades Row 1, Row 2 and stationary blades
9 Dimensional check on turbine wheel diameter
10 Install/re assembly new blades and shroud on 1st and 2nd stage and stationary blades
11 Machine shroud to OEM dimension
12 Fabricate dummy shaft for low speed balancing
13 Balancing according per API 612/678 standard
14 Demagnetizing turbine wheel Max 3 Gause
15 Complete balancing report
16 QC and Final Inspection17 Joint Final Inspection
18 Preservation Rotor and Pack
19 Provide Technical Repair report and Sertificate of Conformity
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Repair Quality Plan
Repair Rotor
Re air Process
ICmponentR
epairable ?
YES
NO
Received from Customer
Engineering Evaluations
Disposition by
Enginering
* Blast Clean and NDT
* Visual Inspection* Dimensional Check
Incoming Inspections
* Damage Level
* Incoming Inspection Report
* Repair Procedure
* Remove old shroud and Blades
* Fabricate new blades
* Identify with Job No.
* Dimensional Check
* QC Inspection
Is
Component
Acceptable?
Repair Report & Certificate of Conformity
NO
YES
Final Inspections
Return to Customer
Inform to
Customer
* Dimensional Check Wheel
* Install/Re-assy new blades and shroud
* Machining shroud to OEM dimension
* Fabricate dummy shaft
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ENGINEERING PLANNING
REBLADING TURBINE WHEEL GT-1005 B K-I
INCOMING INSPECTION
ob Number : Part No :
ustomers : Pupuk Kaltim Qty : 1 Set
Step No Operation Description Data Form Description Operation Complete Operation VerifiedOperation
ApprovedDate
01 eceiving inspect. Receiving Inspection Form
02 Identify with Job# N/A
FENGINEERING PLANROTOR REPAIR
04 imensional check Dimensional Check Form
05 DT & Visual inspect for damage Mapping
QC TOLLGATE
06 END INCOMING PACKAGE WITH FORMS TO ENGINEERING
Planned by: _____________________ Approved by: _____________________
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FENGINEERING PLANROTOR REPAIR
ENGINEERING PLANNING
REBLADING TURBINE WHEEL GT-1005 B K-I
R E P A I R & F I N A L
Job Number : Part No :
Customers : Pupuk Kaltim Qty : 2 SET
Step No Operation Description Data Form Description Operation Complete Operation Verified Operation Approved Date
01 Remove old Shroud and Blades N/A
02 Fabricate New Blades N/A
03 D imensional check Turbine wheel after remove old blades D imensional C heck Form
04 Install New Blades and shroud N/A
05 Machine shroud to OEM dimension N/A
06 Fabricate dummy shaft N/A
07 Balancing Per API 612/678 Balancing Report
08 Demagnetizing turbine wheel Demagnetizzing Report
09 Final NDT inspect & QC Inspection NDT Inspection Form
QC TOLLGATE
10 VERIFY ALLOPERATIONS ARE COMPLETE
11 Final Clean and Pack N/A
12 Release for Shipment N/A
Planned by: _____________________ Approved by: _____________________
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ROTOR STEAM TURBINE, COMPRESSOR, AND PUMP REPAIRROTOR STEAM TURBINE, COMPRESSOR, AND PUMP REPAIR
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One of PT. ALBANY’s Advance Repair Technology.One of PT. ALBANY’s Advance Repair Technology.
• Welding on First Stage Bucket MS 9001E using WRAP process
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One of PT. ALBANY’s Advance Repair Technology.One of PT. ALBANY’s Advance Repair Technology.
• Welding Second stage Bucket MS 9001E using WRAP process
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WELD REPAIR ON THIRD STAGE NOZZLE DIAPHRAGM
KNIFE SEAL
WELD REPAIR ON THIRD STAGE NOZZLE DIAPHRAGM
KNIFE SEAL
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PT. ALBANY ENGINEERING SERVICES
COATING ROOM WITH A VERY GOOD ACOUSTIC
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PT. ALBANY ENGINEERING SERVICESHVOF COATING PROCESS ON FISRT STAGE BUCKET MS 9001E
PT. ALBANY ENGINEERING SERVICESHVOF COATING PROCESS ON FISRT STAGE BUCKET MS 9001E
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PT. ALBANY ENGINEERING SERVICESTBC COATING, PLASMA SPRAY SYSTEM
PT. ALBANY ENGINEERING SERVICESTBC COATING, PLASMA SPRAY SYSTEM
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FUEL NOZZLE TEST BENCHFUEL NOZZLE TEST BENCH
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MOMENT WEIGH FOR ALL FRAME SIZE
BUCKETS / BLADES
MOMENT WEIGH FOR ALL FRAME SIZE
BUCKETS / BLADES
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VERTICAL TURNING LATHE
TO MACHINE NOZZLE DIAPHRAGM, SHROUD BLOCK , ETC
VERTICAL TURNING LATHE
TO MACHINE NOZZLE DIAPHRAGM, SHROUD BLOCK , ETC
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Drop Check & Dimensional Inspection
on Third Stage Nozzle MS 6001B
Drop Check & Dimensional Inspection
on Third Stage Nozzle MS 6001B
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PT. ALBANY ENGINEERING SERVICES
ISO 9001-2008 and OHSAS 18001-2007 SERTIFIED
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PT. ALBANY ENGINEERING SERVICES
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PT. ALBANY ENGINEERING SERVICES
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PT. ALBANY ENGINEERING SERVICES
LOCAL PARTNER
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PT. ALBANY ENGINEERING SERVICES
LOCAL PARTNER
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PT. ALBANY ENGINEERING SERVICES
INTERNATIONAL PARTNER
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PT. ALBANY ENGINEERING SERVICES
INTERNATIONAL PARTNER
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PT. ALBANY ENGINEERING SERVICES
INTERNATIONAL PARTNER
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PT. ALBANY ENGINEERING SERVICES
JL. RAYA PANYAWUNGAN KM.0,8
TELP. : (022) 7796455 (HUNTING),7796466,
FAX. : (022) 7796678, 2013734WEBSITE : www.albanybandung.com
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PT. ALBANY ENGINEERING SERVICES
atur Nuhun