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PT.

ALBANY ENGINEERING SERVICES

JL. RAYA PANYAWUNGAN KM.0,8


TELP. : (022) 7796455 (HUNTING), 7796466, FAX. : (022) 7796678, 2013734
WEBSITE : www.albanybandung.com

PT. 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

MISSION & APPLICATION


MISSION
1. To Provide Support For Full
Service Capability

2. Become The Customers Natural


Choice
~
Quality
~
Cost
~
Delivery

3. To be the Repair Service Centre Of


Excellence in Indonesia.

APPLICATION
GE

:
Frames 3, 5, 6, 7 and 9

Westinghouse : W191, W251,


W501.

Mitsubishi

: MW 701 D.

ABB

: Types 13 E

Siemens

: V94

Various Steam Turbine Rotor,


Compressor, Pumps, etc
3

NORMALLY INSPECTION & REPAIR INTERVAL

CERTIFIED MAN POWER REQUITED

BUSINESS FOCUS
REPAIR OF ROTATING EQUIPMENT SERVICES

REPAIR OF HEAVY DUTY GAS TURBINE COMPONENTS

- Gas Turbine

Gas Turbine Bucket

Centrifugal Compressor

Gas Turbine Cold section ( Compressor ) Blades

Single & Multi Stage Pump

Turbine Power Nozzle / Vane Segment

Steam Turbine

Transition Pieces.

Turbo Charger

Combustion Liners / Combustion Basket.

Hydro

Shroud Blocks.

Reciprocating

Fuel Nozzles.
Compressor Stator.
Bul Horn.
Diaphragm.
Support Ring.
Bearings.
Burner.

Screw Compressor Rotor

6
TP after Repair

THE MAJOR REQUIRED FACILITY

WELDING ( TIG )

VACUUM FURNACE

BLASTING EQUIPMENT

NDT

VERTICAL TURNING LATHE OR UNIVERSAL MILLING MACHINE

PLASMA COATING EQUIPMENT

HVOF COATING EQUIPMET

HORIZONTAL LATHE MACHINE

BALANCING MACHINE

High Capacity Horizontal Lathe

7
Semi Robotic Plasma Coating

BASIC SERVICE TECHNOLOGY ( COND )


REPAIR OF VARIOUS
TURBINE COMPONENT
Engineering

Plan Process &


Specification

Quality Plan and Quality


Assurance
Turbine Bucket / Blades

Damage Criteria / Repair


Category

Work Scope

Delivery Schedule
Diaphragm / Stator Vane / Turbine8Nozzle
8

BASIC SERVICE TECHNOLOGY


ENGINEERING PROCESS &
SPECIFICATION

GT29/33 COATING by HVOF

Function of its components.

Operating condition : Temperature,


Pressure, Speed, Control Device, etc.

Check the original material and


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 GT29
9

BASIC SERVICE TECHNOLOGY ( CONTD )


QUALITY PLAN AND QUALITY ASSURANCE
1. Provide the references of any repair
process, I.e : Weld per ASME IX,
Balancing per API, Heat Treatment per
Standard etc.
2. Provide checking and quality test in the
repair specimen I.e : How to check the
welding Quality, Coating Quality,
Roughness Test, etc.
3. Provide special fixture, go / no-go tools, and
another special tool (Harmonic check,
Computerize Measuring Machine/Three Axis
Dimensional Check, etc.
4. Provide the simulation test if required
(Airflow Test, Fuel Nozzle Flow Test, etc.)
5. Provide warranty, guarantee, certificate of
conformity, Liability Insurance, etc.)

Shroud Block Fixture for Machining to Dimension


10

MAJOR EQUIPMENT &


MAJOR REPAIR PROCESS ( CONTD )
DIAPHRAGM SEAL
Full NDT Inspection
Weld build up or satellite coating
Replace all knife seal
Machine to the original
drawing dimension
Assembly with Special fixture

Shroud Block Fixture for Machining to Dimension

Damaged Shrouds

Shrouds After Repair


11

MAJOR EQUIPMENT & MAJOR REPAIR PROCESS


NOZZLE REPAIR
o

Coupon manufacture

Trailing edge coupon restoration

EDM machining

Downstream Deflection correction

Fixture repaired components

Hydrogen bright annealing

Solution age run

Nozzle segment before Repair

Nozzle segment after Repair


12

MAJOR REPAIR PROCESS ( CONTD )


BUCKET AND BLADES
Cleaning
Stripping
Tip build ups
Angel wing restoration
Moment weighs
NDT
Coatings
Stellite inlay

REPAIR PROCESS ( BLENDING )

Ultrasonic Test to Insures minimum wall thickness


requirements are met

BUCKET AFTER REPAIR

13

MAJOR EQUIPMENT & MAJOR REPAIR PROCESS


NOZZLE REPAIR
o

Coupon manufacture

Trailing edge coupon restoration

EDM machining

Downstream Deflection correction

Fixture repaired components

Hydrogen bright annealing

Solution age run

Nozzle segment before Repair

Nozzle segment after Repair


14

GAS TURBINE PART REPAIR

Repair on first Stage bucket Airfoil of MS 9001E

ROTOR BLADE REPAIR

ROTOR REPAIR

ROTOR
Repair Work scope
JOB NO.
CUSTOMER
DESCRIPTION

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

:
: Pupuk Kaltim
: Turbine Wheel GT-1005-B

DRAWING NO.
SERIAL NO.
QUANTITY

:
:
: 1 SET

Perform receiving inspection, Photograph as received condition


Blast Clean turbine wheel with Aloxs
NDT & Mapping all Defect as required
Visual Inspection
Provide Incoming Inspection Report
Remove old shroud and blades 1st and 2nd stage and stationary blades
Dimensional check on T-Slot or Groove and NDT
Fabricate new Blades Row 1, Row 2 and stationary blades
Dimensional check on turbine wheel diameter
Install/re assembly new blades and shroud on 1st and 2nd stage and stationary blades
Machine shroud to OEM dimension
Fabricate dummy shaft for low speed balancing
Balancing according per API 612/678 standard
Demagnetizing turbine wheel Max 3 Gause
Complete balancing report
QC and Final Inspection
Joint Final Inspection
Preservation Rotor and Pack
Provide Technical Repair report and Sertificate of Conformity

Repair Quality Plan


Repair Rotor
Received from Customer * Identify with Job No.
Incoming Inspections
Engineering Evaluations

NO

* Blast Clean and NDT


* Visual Inspection
* Dimensional Check
* Damage Level
* Incoming Inspection Report
* Repair Procedure

ICmponentR
epairable ?

Disposition by
Enginering
YES

* Remove old shroud and Blades


* Fabricate new blades
* Dimensional Check Wheel
* Install/Re-assy new blades and shroud
* Machining shroud to OEM dimension
* Fabricate dummy shaft

Repair Process

Inform to
Customer

Final Inspections
* Dimensional Check
* QC Inspection
Is
Component
Acceptable?

NO

YES
Repair Report & Certificate of Conformity

Return to Customer

FENGINEERING PLAN
ROTOR REPAIR
ENGINEERING PLANNING
REBLADING TURBINE WHEEL GT-1005 B K-I
INCOMING INSPECTION

Step No

Job Number

Part No

Customers

: Pupuk Kaltim

Qty

: 1 Set

Operation Description

Data Form Description

01

Receiving inspect.

Receiving Inspection Form

02

Identify with Job#

N/A

03

Alumunium Blast Clean

N/A

04

Dimensional check

05

NDT & Visual inspect for damage

Operation Complete

Operation Verified

Dimensional Check Form

Mapping

QC TOLLGATE
06

SEND INCOMING PACKAGE WITH FORMS TO ENGINEERING

Planned by: _____________________

Approved by: _____________________

Operation
Approved

Date

FENGINEERING PLAN
ROTOR REPAIR
ENGINEERING PLANNING
REBLADING TURBINE WHEEL GT-1005 B K-I
REPAIR & FINAL
Job Number

Part No

Customers

: Pupuk Kaltim

Qty

: 2 SET

Step No

Operation Description

Data Form Description

01

Remove old Shroud and Blades

N/A

02

Fabricate New Blades

N/A

03

Dimensional check Turbine wheel after remove old blades

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

08

Demagnetizing turbine wheel

09

Final NDT inspect & QC Inspection

Operation Complete

Dimensional Check Form

Balancing Report

Demagnetizzing Report

NDT Inspection Form

QC TOLLGATE

10

VERIFY ALL OPERATIONS ARE COMPLETE

11

Final Clean and Pack

N/A

12

Release for Shipment

N/A

Planned by: _____________________

Approved by: _____________________

Operation Verified

Operation Approved

Date

ROTOR STEAM TURBINE, COMPRESSOR, AND PUMP REPAIR

One of PT. ALBANYs Advance Repair Technology.

Welding on First Stage Bucket MS 9001E using WRAP process

One of PT. ALBANYs Advance Repair Technology.

Welding Second stage Bucket MS 9001E using WRAP process

WELD REPAIR ON THIRD STAGE NOZZLE DIAPHRAGM


KNIFE SEAL

PT. ALBANY ENGINEERING SERVICES

COATING ROOM WITH A VERY GOOD ACOUSTIC

PT. ALBANY ENGINEERING SERVICES


HVOF COATING PROCESS ON FISRT STAGE BUCKET MS 9001E

PT. ALBANY ENGINEERING SERVICES


TBC COATING, PLASMA SPRAY SYSTEM

FUEL NOZZLE TEST BENCH

GO- no GO inspection process

Drop Check on the Vertical of Floating seal Slot Areas

MOMENT WEIGH FOR ALL FRAME SIZE


BUCKETS / BLADES

VERTICAL TURNING LATHE


TO MACHINE NOZZLE DIAPHRAGM, SHROUD BLOCK , ETC

Drop Check & Dimensional Inspection


on Third Stage Nozzle MS 6001B

PT. ALBANY ENGINEERING SERVICES

REPAIR ON INTERMEDIATE LINER OF ABB GAS TURBINE


MODEL 13 E, TOP URGENT STATUS WAS REQUESTED BY
CUSTOMER ( PT. INDONESIA POWER PRIOK )

PT. ALBANY ENGINEERING SERVICES

ISO 9001-2008 and OHSAS 18001-2007 SERTIFIED

PT. ALBANY ENGINEERING SERVICES

PT. ALBANY ENGINEERING SERVICES

PT. ALBANY ENGINEERING SERVICES


LOCAL PARTNER

PT. ALBANY ENGINEERING SERVICES


LOCAL PARTNER

PT. ALBANY ENGINEERING SERVICES


INTERNATIONAL PARTNER

PT. ALBANY ENGINEERING SERVICES


INTERNATIONAL PARTNER

PT. ALBANY ENGINEERING SERVICES


INTERNATIONAL PARTNER

PT. ALBANY ENGINEERING SERVICES


INTERNATIONAL PARTNER

PT. ALBANY ENGINEERING SERVICES

JL. RAYA PANYAWUNGAN KM.0,8


TELP. : (022) 7796455 (HUNTING),
7796466,
FAX. : (022) 7796678, 2013734
WEBSITE : www.albanybandung.com

PT. ALBANY ENGINEERING SERVICES

Hatur Nuhun