POWERGEN MARKET - CAPABILITIES

OUR OFFERINGS FOR POWERGEN

• HYDRAULIC TOOLS
• BOLTING PRODUCTS
• MACHINING PRODUCTS
• HLT – HEAVY LIFT TECHNOLOGY
• EQUIPMENT RENTAL
• BOLTING & ONSITE MACHINING SERVICES
• INDUCTION HEATING
• SPECIALTY ONSITE MACHINING
• PROCESS & PIPE LINE SERVICES
HYDRAULIC TOOLS

Tools for the Transportation, Installation and Maintenance of Steam and Gas turbines.

Transportation & Positioning Positioning/Skidding Lifting and Positioning

Hydraulic Gantries Skidding Systems EVO Synchronous Lifting Systems
Rated Capacity 67.5 – 1,178 tons Rated Capacity 281 Tons Lift Points 4, 8 or 12
Lift Height 133 - 472in Stroke 24in Accuracy +/-0.04”
HYDRAULIC TOOLS

Tools for the Transportation, Installation and Maintenance of Steam and Gas turbines.

Turbine Casing Support General Tools Turbine Casing - Bolting

Mechanical Jacks Cylinders, Pumps, Pullers, Standard Hydraulic Torque Wrenches
Rated Capacity upto 24 ton Presses, Punches & Turbine Specific Bolt Tensioning Kits
Stroke 14in Mechanical Actuators Tools for Separation & Alignment
TORQUE PRODUCTS

TOOLS FOR ASSEMBLY & MAINTENANCE OF BOLTED JOINTS

Nominal Torque output Maximum Torque Output Nominal Torque output Maximum Torque Output
35.455NM 28,002 ft-lbs 8135 NM 1015 – 10.845 NM
Square Drive Range Hexagon Range Square Drive Range Torque Ratio
¾ - 2.1/2 Inch 7/8 – 6.1/8” 1 - 1.1/2 Inch 3:1 – 52:1
SPECIALITY TENSION

TOOLS FOR CRITICAL FASTENING APPLICATIONS IN WIND GAS AND STEAM TURBINES

Bolt Range Load Range Multi Stud Tensioning Systems

M20 – M72 FTR - 0 – 308 Tons Light Weight Design
Load Range FTE – 0 – 86 Tons 100% Coverage
Maximum Operating Pressure Asymmetric Rams
23 – 334 Tons Integrated load measurement
Maximum Operating Pressure 21,750 psi /1500 bar
19,575 – 21,750 PSI
GAS TURBINE KITS

Turbine Kits for General Electric - 3, 5, 6, 7, 9* LMS100 engines

Turbine Kits for Alstom – GT11, GT13, GT26 and GT24
Turbine Kits for Siemens and MHI – 501F, 501G, and V84
GAS TURBINE KITS – GT13E2

Turbine Kits for Alstom – GT11, GT13, GT26 and GT24 are also available
EXAMPLE COVERAGE

Hydraulic Tensioner Wind Blade App Hydraulic Nuts – Nuclear Generator Hydraulic Tensioners – GT

Hydraulic Torque Wrench – ST Multi-Stud Tensioner – GT

MST – Manway access
GT – EXPERIENCE EXAMPLES
GT – ROTOR FIELD SERVICING TOOLING

OEM SPEICIFIED AND

APPROVED
GE, SIEMENS, MHI &
HARBIN
GT GENERATOR ALIGNMENT
BOLTING SERVICES -EXAMPLES
BOLTING SERVICES -EXAMPLES
BOLTING SERVICES -EXAMPLES
BOLTING SERVICES -EXAMPLES
GT – CUSTOMIZED ENGINEERED SOLUTIONS

MARRIAGE JOINT TORQUE WRENCH - GERT

THE CHALLENGE

• Un Bolt Marriage Joint Of The 7FA

And 9FA Turbines
• Take Apart Sections That Join The
Compressor Assembly With The
Combustion Assembly Of The Rotor

THE CONSEQUENCES

• Tool Capable Of Producing Required

Torque In Confined Spaces
• Forced To Improvise Using Non Bolting
Equipment Which Compromise Safety
• Typical Joint Taking In Excess Of Two
Shifts To Disassemble

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ENHANCED TURBINE COUPLING TOOL - ETCT
Patent Pending
 CURRENT COUPLING PROCESS CONCERNS

• UNSAFE
• Ergonomic Issues
• Time (2 Shifts?)
• Weight
• Difficult to Manage
• Failure Mode (Not Controlled)
• Correct Engagement Concerns
• Bleeding of Hydraulic System under Operation
• Procedure for bolting
• Cleaning of tapered thread
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 ETCT SAFETY FEATURES

• Tools Fully Supported by Carriage Assembly

• Multiple Mandrels hand fit to ensure proper engagement
• Maximum lift weight less than 70Lbs.
• Weightless during operation (Make Up & Break Out)
• Automatic Lock System
• Safe Self-Contained Failure Mode
• Remote Controlled Pump
• Safety Pressure Setting on Pump Unit

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 MACHINING PRODUCTS RANGE - MIRAGE

Flange Facing Orbital Milling Pipe cutting

Diamond wire saw

Band saw Hot tap & Line stop Linear mills Drilling & Tapping

Line boring
Shaft Machining Power Supplies & Tooling Custom Engineering
FLANGE FACING

Mirage Flange facers are used to machine raised face, Ring Joint (RTJ), Compact, heat
exchanger header/covers, lens ring, hub profile flanges and crane pedestals

Internally Mounted Externally Mounted Internal / External

2 – 120” (50 – 3050mm) 0 – 24” (0 – 610mm) 0 – 157” (0 – 4000mm)
PIPE CUTTING AND BEVELING

Pipe cutting and beveling for new pipeline preparation, pipe spools, flange removal,
pipeline repairs, casing cutting and steam line repair

MS – medium duty HD – Heavy duty

NB – narrow body 4 – 48” (100 – 1219 mm)
2 – 36” (13 – 915mm) 16 – 180” (405 – 4572mm)
PIPE CUTTING AND BEVELING - EXAMPLES
MM 180 Applications
ORBITAL MILLS

Orbital mills for machining large flanges, slew ring bearing faces (crane pedestals,
excavators, loaders, drag lines) thruster flanges, Hydroelctric dam repairs, crane
pedestals, wind turbine blades and towers

WP
OM 70 – 190” (1.8 – 4.8m)
98 – 315” (2.5 – 8.0m) Optional hydraulic base
Supplied complete with base
LINEAR MILLS

Mirage 2, 3 and Gantry milling machines are used in heat exchangers, shaft keyways,
turbine casings, motor/pump mounting, large fabrications

GM - gantry
MR – 2 axis MRY – 3 axis 40 – 393” (1m – 10m)
40 – 120” (1m – 3m) 40 – 120” (1m – 3m) HD ball screw up to 6m
Rack feed up to 10m
HOT TAPPING & LINE STOPPING

Hot Tapping and Line Stopping machines for pipeline intervention under pressure,
pipeline expansion, new branches, valve insertion / repair and subsea pipeline repair

MHT - medium pressure CHT - High Pressure LSA- Line stop Actuators
1/2 – 60” (13 – 1525mm) 3 – 48” (75 – 1219 mm) 2 – 48” (50 – 1219mm)
0 – 1480 psi (102 bar) 0 – 5000 psi (348 bar) 0 -1480psi (102 bar)
DRILLING & TAPPING

Mirage drilling and tapping machines are used primarily for stud removal and repair, large
flange drilling, pump and motor mounting. The Double drill units are used in
decommissioning of platforms to install lift pins.

HT - drills
T – tapping units DDU – DDI double drill
1/2 – 6” (13 – 152mm) 16 – 48” (405 – 1219mm)
1 – 7.5” (25 – 190mm)
LINE BORING

The Mirage range of line boring machines are used for ships stern tubes, A-frames,
gearboxes, turbine casings, Excavator, loader buckets and crane booms

MLB LB LB300
6 – 80” (150 – 2032mm) 36 – 120” (915 – 3050mm)
1.5 – 24” (38 – 610mm)
MS-JTL SHAFT MACHINING

• Capable of machining shaft diameters from 4 in. (101.6 mm) to 32.5 in. (825.5 mm)
• Assortment comprised of five machines
Unit of A B C D
Model Measure (Shaft Range) (Clearance) (Overall Length) (Travel)
Std (in) 4 - 8.875 25.5 40 25
MS-JTL 8
Metric (mm) 101.6 -225.4 647.7 1016 635
Std (in) 8 - 14.5 33.5 48 32
MS-JTL 14
Metric (mm) 203.2 - 368.3 850.9 1219.2 812.8
Std (in) 14 - 20.5 39.5 48 32
MS-JTL 20
Metric (mm) 355.6 - 520.7 1003.3 1219.2 812.8
Std (in) 18 - 24.5 43.5 48 32
MS-JTL 24
Metric (mm) 457.2 - 622.3 1104 1219.2 812.8
Std (in) 20 - 26.5 45.5 48 32
MS-JTL 26
Metric (mm) 508 - 673.1 1155.7 1219.2 812.8
Std (in) 26 - 32.5 51.5 48 32
MS-JTL 32
Metric (mm) 660.4 - 825.5 1308.1 1219.2 812.8
Std (in) 30 - 36.5 55.5 48 32
MS-JTL 36
Metric (mm) 762 - 927.1 1410.6 1219.2 812.8
 SHAFT MACHINING

Refurbishing horizontal and vertical shafts without

having to disassemble or rotate the shaft .

SAVES CUSTOMERS TIME AND MONEY

JOURNAL TURNING LATHE – APPLICATION
ORBITAL LATHES
ORBITAL LATHES
 HEAVY LIFTING TECHNOLOGY
OVERHAUL SPECIAL SOLUTIONS

HYDRAULIC GANTRIES STRAND JACKS SKIDDING SYSTEMS

SYNCHRONOUS LIFTING SYSTEMS SELF-PROPELLED MODULAR UNITS

JACK UP SYSTEMS
HLT - OVERHAUL SPECIAL SOLUTIONS
GENISYS™ IV PORTABLE CNC MILLING MACHINE

4 -AXIS CNC MILLING MACHINE FOR

ADVANCED BOLT EXTRACTION &
THREAD REFURBISHMENT
 GeniSYS™ IV Portable CNC Mill Specifications
The New GeniSYS IV has many up graded features from previous
versions including increased capacity and cutting speed

Unit of Measurement
geniSYS II
Std Metric
Hole Min .875 (in) 22.23 (mm)
Diameter Max 12 (in) 304.8 (mm)
Max Hole Depth 17.8(in) 452.12 (mm)
Max X-axis Travel 8 (in) 203.2 (mm)
Max Y-axis Travel 8 (in) 203.2 (mm)
Max Z-axis Travel 20 (in) 508 (mm)
Spindle Speed 2500 (RPM)
Spindle Motor 5.3HP 4kW

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 GeniSYS™ IV Portable CNC Mill Installation

GeniSYS Iv milling machine is

positioned over the area of work

Desired tooling is installed in

An application specific steel mounting the machine
plate is positioned on the workpiece

The geniSYS II is now ready to Machine is then attached to the

perform bolt extraction or thread mounting plate with fixturing
refurbishment
Squaring the machine is done
by adjusting the leveling
screws and hol down clamps
along with a dial indicator

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 GeniSYS™ IV Portable CNC Mill

INTERNAL THREAD REPAIR

Threads Refurbishment

Enlarging & Forming New Threads

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 GeniSYS™ IV Portable CNC Mill
After set-up & Threads Refurbishment
centering the
machine, the Genisys
program begins
machining

Removed material
The first pass cores
out the center of the
bolt (Minor Diameter)

The second pass remove the

remainder of the bolt material
as close as possible leaving
the crest of the thread and
put out by grip pillar.

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 GeniSYS™ IV Portable CNC Mill
Enlarging & Forming New Threads

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 GeniSYS™ IV Portable CNC Mill
Huntsman Singapore
F-A-3 REACTOR

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 GeniSYS™ IV Portable CNC Mill

Huntsman Singapore
F-A-3 REACTOR

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 GeniSYS™ IV Portable CNC Mill

Huntsman Singapore
F-A-3 REACTOR

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 GeniSYS™ IV Portable CNC Mill

Taiwan FPCC
RDS#2 High Pressure Separator

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 GeniSYS™ IV Portable CNC Mill

Taiwan FPCC
RDS#2 High Pressure Separator

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 GeniSYS™ IV Portable CNC Mill
Taiwan FPCC RDS#2 High Pressure Separator

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APPLICATION PHOTOS – PIPE CUTTING/BEVELLING
APPLICATION PHOTOS – FLANGE FACING
FLANGE FACING - 60” MW & 72” FLOATING HEAD
Flange Facing - Tube sheet back facing & Valve
Flange
FLANGE FACING - HEAT EXCHANGER TUBE SHEET
Flange Facing -Quickface on 3” flange and 82”
bearing face
FLANGE FACING - MACHINING OF TOP AND BOTTOM
FLANGE ID MOUNT MACHINE
FLANGE FACING - MACHINING OF TOP AND BOTTOM
FLANGE ID MOUNT MACHINE
SPECIALITY MACHINING – SG SEGMENTATION, RPV
STUD REMOVAL, VALVE SEATING

Specialty Machining – Engineering – Service Manpower

Specialty Pipe Cutting, Field Service Engineering

Boring, Tapering and Specialty Milling
Pipe Replacement…Pipe Cutting, Heat Treating, Bolting
Stud Removal and Drilling/Rethreading
SPECIALITY MACHINING – TURBINE OF A NUCLEAR
POWER PLANT

CRITICAL, ACCURATE, MACHINING , ENGINEERING – SERVICE MANPOWER

Cross Over Flange Machining

Shaft Machining, Grinding and Boring
Coupling Machining and Bolting
INDUCTION HEATING
WHAT IS INDUCTION HEATING?

A Form Of Heating That Uses Energy From A Magnetic Field

No flame, therefore no combustible fuels/oxidant ratios needed

No contact: magnetic fields can travel through air, therefore workpiece can be moving
during heating process
TYPICAL EQUIPMENT

100 KW UNIT INDUCTION WANDS

CHILLER UNIT

NUT HEATING COILS

APPLICATION EXAMPLES

STUD HEATING NUT HEATING ROTOR HEATING

APPLICATION EXAMPLES

BOILER TUBE HEATING

APPLICATION EXAMPLES

THERMAL EXPANSION MISCELLANEOUS HEATING

HYDRATIGHT PIPELINE & PROCESS SERVICES

Hydratight PPS services lines revolve primarily around pre-commissioning, commissioning, and
regular maintenance servicing events

Specifically, we provide an integrated services platform to the energy industry

Current portfolio consists of 12 complementary services, plus we have access to FQE Chemicals
Hydratight PPS Service Lines

Engineering

Lube Oil Degassing Filtration &

Air Blowing
Flushing Decontamination Heating

Chemical Nitrogen
Steam Cleaning Services
Blowing
LUBE OIL FLUSHING

Why do we perform a Lube Oil Flushing?

Cleanliness Scale

Particles to be Removed Service

Fine Particles only (incl. Mill Scale) Chemical Cleaning*

Any Size Particles (incl. mill scale) Steam Blowing, HP Air Blows

Fine Particles (excl. mill scale) High Velocity Flush (Oil Flush)

Fine Particles (excl. mill scale) Pulse Blow (applicable to small IDs)

Medium + Size Particles LP Air Blows, Low Velocity Flush

Large Size Particles only Continuous Air Blow, Fill-and-drain

* Has to be combined with an additional service to remove large debris

LUBE OIL FLUSHING

Cleaning & flushing of hydraulic & lube oil systems is employed to insure that new rotating & hydraulic
equipment will start up & operate as designed
 Greatly reduces the potential of premature failure of equipment
Contaminants foul & become trapped in bearing races, in rotating equipment this will cause significant
damage

 Rust
 Scale
 Slag
 Sand
 Dirt
 Oils can also contaminate
Particles as small as five microns in size can cause significant damage if allowed to remain or become
trapped in the process system
LUBE OIL FLUSHING
Relative size comparison of particles of some common materials
Why do we require Oil Flushing ? Particle Size Comparison
 Particulate can be microscopic and still cause 159 μm 100 mesh screen opening
damage. The scale of particles that we are 100 μm Table salt
filtering down to is around 1 micron 74 μm 200 mesh screen opening
60 μm Pollen
40 μm Human lower limit of visibility
2 μm Bacteria
Typical dynamic film thickness for equipment
Component Thickness, μm
Roller bearings 0.4 to 1
Ball bearings 0.1 to 0.7
Journal bearings 0.5 to 25
Gears 0.1 to 1
Seals 0.05 to 0.5
Servo valves: - orifice 130 to 450
- flapper to wall 18 to 63
- spool to sleeve 1 to 4
Hydraulic Actuators 25 to 250
LUBE OIL FLUSHING

Applications within the Energy industry for this process include:

 Cleaning of hydraulic control systems

 Cleaning of Subsea control lines
 Compressor lube oil system cleaning
 Marine vessel control system cleaning
 Steam & Gas Turbines lube systems
 High efficiency heat exchangers
 On Line Oil Filtration
 Electrical Transformer Oil Filtration
LOF services are used to extend the life cycle of lubrication systems during pre-commissioning
commissioning & following periodic maintenance & repair services

Service is key in any facilities preventative maintenance program where equipment failure is
not an option
LUBE OIL FLUSHING

Types of equipment that benefit from this process include:

Large Pumps
Turbines
Compressors
Hydraulic Systems
 Supply/Return Lines (bearings)
Emergency Pump
Lube Oil Console:
 Oil Reservoir/Run Down Tank
 Main/Auxiliary Pump
 Filters/Coolers Gas Turbine with Lubrication Oil Piping
 TCV, FCV, PCV (Temperature Control Valve, Flow Control Valve, Pressure Control Valve)
CHEMICAL CLEANING – PRE OPERATIONAL & POST
OPERATIONAL

What is Chemical Cleaning

 Chemical cleaning is the process of

cleaning/removal of unwanted contaminates from
metal surface using appropriate chemicals.

 Industrial chemical cleaning was developed back

in 1930’s by oil and gas industry and since then in
practice and adopted by many industrial sectors
over the time.
CHEMICAL CLEANING – WHY?

 Pre-operational cleaning is performed to

chemically clean equipments, piping etc
before put them in service.

 Post-operational cleaning is performed

when the system’s efficiency is reduced
because of contamination/deposits over a
period of time in operations.

 Protection of equipments and increased

efficiency.
CHEMICAL CLEANING – APPLICATION WITHIN THE
INDUSTRY

Some of the Industries we serve

 Power & Utility industry. Power plant equipment’s,

boilers, feed water system, cooling water system
etc.

 Oil & Gas / Petrochemical industry. Equipment’s like

boilers, utility lines (oxygen, nitrogen), compressor
lines, hydraulic/lube oil lines, BFW lines etc.

 Steel industry, Cement industry & manufacturing

facilities etc.
CHEMICAL CLEANING – TYPE OF POWER PLANT
EQUPIPMENT WHICH WILL REQUIRE THIS SERVICE

• Feedwater Heaters
• Superheater
• Reheater
• Cooling Water Systems (open & closed)
• Boiler
• Water Walls
• High Pressure Turbine
• Boiler Feed Pumps
• Hydrogen Coolers
• Forced/Induced Fan Hydraulics
• Misc. Water Cooled Equipment
 CHEMICAL CLEANING – EQUIPMENT

Hydratight has several custom pieces of equipment to perform chemical cleaning.

FS 4000
FS 2000

500 gallons/minute pump 1000 gallons/minute pump

80 kW heater 144 kW heater
4 bag filter vessels (2) 8 bag filter vessels (2)
CHEMICAL CLEANING – CLEANLINESS STANDARDS

Examples/results of chemical cleaning

CHEMICAL CLEANING – CLEANLINESS STANDARDS

Examples/results of chemical cleaning

STEAM BLOWING

Examples/results of chemical cleaning