A comprehensive presentation showcasing Cullum Aftermarket Products and Services

1. Cullum Aftermarket
Products and Services
Onshore and Offshore

2. Mechanical & Electrical Field Service Team
• Highly skilled team of Mechanical and
Electrical Field Service Engineers (FSEs),
offering:
• Installation Services for:
• New build
• Maintenance Repair & Overhaul (MRO)
Services
• Onshore & offshore support
• Global deployment
• Inspection and Technical Service Support

3. Refurbishment, Modifications and Life Extension:
“End to End Solutions”
• Cullum’s Qualified Refurbishment Team offer:
• CDM Co-ordination
• Engineering Inspection & Design
• Project Management
• Manufacture
• Installation Services:
• Mechanical & Electrical Field Service Engineers
• Maintenance, Repair & Overhaul (MRO) for Gas Turbines, Driven
Equipment and Auxiliary Systems:
• Air Filtration Systems – including EPA (HEPA)
• Combustion Air Intakes
• Acoustic Enclosure & Ventilation Systems
• Combustion Exhaust systems
• Emissions Control Systems
• Site Services
• Spare Parts

4. Design & Solution Flexibility
Project customisation for all equipment, engineered for the specific applications and
conditions, including:
• Filtration for specific environments
• Environmental Challenges:
• Salt Environments
• Extreme Heat
• Dust and Sand Storm Environments
• Seismic, Pitch, Roll and High Wind Loads
• Blast Loads
• Fire Rated Enclosures
• Project Noise Levels
• All Types of Onshore & Offshore Installations – Fixed and Floating Installations

5. What we can do and
what’s important to us

6. CDM Services & Site Management
• Services include:
• Providing support to the client
• Fulfilling the role of Principle Contractor
• Fulfilling the role of Principle Designer
• Acting in the role of:
• Designer
• Contractor

7. HSE Excellence – Zero Harm Culture
• Zero Harm Culture at the centre of everything we do
• OHSAS 18000 Accreditation
• Alignment with our customers to achieve the highest
standards of HSE
• 6 Pillars of our Safety Culture to drive Behavioural
Safety
• Robust Risk Assessment and Method Statement
Processes
• Qualified team with depth and experience

8. OEM Installation Services
Services include:
• Support for Offshore and Onshore Installations
• Return to Cullum base overhauls and repairs
• Silencer element repair or replacement and refit
• Ducting maintenance, repair or replacement
• Coating systems (painting)
• Replacement part sourcing or Cullum manufacture
• Flexible joint repair or replacement
• Plenum refurbishment
• Plenum floor re-painting or stainless steel lining
• FOD investigations

9. Site Management
• Full site management of all site based activities
• Compliance with CDM 2015 regulations
• Site establishment and co-ordination
• Risk Assessments and Methods Statements (RAMS)
• Includes management of all site based activities:
• Scaffolding
• Rigging and lift plans
• Lifting – removal and refit
• Site based refurbishment
• Mechanical and Electrical works
• Lagging and cladding
• Roof sealing
• Site and project specific work scopes
• Much more

10. Small Works to Specialist/Mini-EPC
Expansion Joint Replacement Project
• Range of works:
• Taking on small site based
activities and projects to
taking on larger project Work
Scopes for retrofit and
refurbishment activities
Major Emissions Reduction Catalyst Project

11. Engineering Services
• Engineering design and consultancy services:
• Mechanical engineering services
• Design studies and investigations
• Feasibility and optioneering studies
• Project execution and fulfillment
• Electrical engineering services:
• Design studies and investigations
• Feasibility studies
• DSEAR studies, investigations and compliance
• Project execution and fulfillment
• Acoustic and noise studies
• Project noise compliance studies
• Investigations and noise surveys
• Acoustic design services
• Site Surveys, problem solving, optioneering and obsolescence
reviews

12. • Support for Turbomachinery and other air handling
systems:
• Offshore and Onshore Filter Systems
• Static (high, medium and low velocity) and Pulse Filter
(horizontal and vertical cartridge)
• Filter element and cartridge exchange (Supply and Fit)
• Part sourcing and replacement services, using Cullum’s
manufacturing facility
• Filter Optimisation
• Trouble shooting (Site Problems)
• Improvement Options and Studies
• EPA (former HEPA)
• Reducing or increasing the number of filter stages
Air Filtration Systems

13. • Filter House Upgrades
• Housing maintenance
• Coating systems (painting)
• Replacement parts
• Housing modifications and Upgrades
• Housing replacement
• Roller shutter door and dehumidification system
retrofits and maintenance – onshore and offshore
• Anti-icing or Chilling System retrofit or repairs
• Value analysis for improved levels of filtration
Air Filtration Systems

14. Combustion Intake Systems
• Machine critical ducted systems and noise control features
• Offshore and Onshore Installations
• Silencer element repair, replacement or refit
• Ducting maintenance, repair or replacement
• Coating systems (painting)
• Replacement part sourcing or Cullum manufacture
• Flexible joint repair or replacement
• Plenum refurbishment, including door sealing, hinges and latches
• Plenum floor re-painting or stainless steel lining
• FOD investigation and risk assessments
• Replacement parts including design, manufacture and re-installation

15. Enclosure Maintenance, Repair and
Replacement
• Asset protection and personnel safety – Fire Protection and
Suppression System Integrity
• Support for all machinery enclosures for noise reduction, weather
protection or fire extinguishant retention
• Offshore and Onshore Installations
• Repair, replacement or refit
• Door seals and door furniture – Hinges, Latches
• Material integrity (corrosion)
• Coating systems (painting)
• Replacement part sourcing
• Cullum manufacture/service
• Replacement parts including design, manufacture and re-installation

16. Ventilation System Maintenance & Repair
• Ventilation System Design Verification
• Upgrades and Maintenance
• Hazardous Area Compliance – ATEX, UL, NEC, CSA etc.
• Component repair, replacement and refit
• Coating systems (painting)
• Replacement part sourcing or Cullum manufacture
• Fan unit maintenance, repair, upgrade or replacement
• Flexible joint and damper repair or replacement
• Filtration optimisation and upgrades

17. Combustion Exhaust and Stack
• Combustion Exhaust System Maintenance, Repair and Overhaul – including
Offshore and Onshore Installations
• Expansion Joint repair & replacement
• Hot exhaust system design repair or replacement
• Cold case design solutions for all Gas Turbines
• Silencer repairs and baffle replacement with high performance acoustic
absorption systems
• Exhaust stack inspection, maintenance and repair
• Exhaust collector repair and replacement
• ATEX compliant replacement exhaust systems

18. Combustion Exhaust and Stack
• Ducting maintenance, repair or replacement
• High Temperature coating systems
• Replacement part sourcing
• Replacement and repair of exhaust cladding systems
• Cullum manufacture of replacement parts
• High Integrity Products (Hot Bolt, CCRM etc.)
• Retrofit CEMS ports and complete CEMS installations

19. Waste Heat Recovery Unit (WHRU) & Damper
Systems
• WHRU casing repairs and overhaul
• Internal lining replacement or repair
• External cladding replacement or repair
• WHRU bundle refurbishment or replacement
• WHRU casing replacement – Hot and Cold casing designs
• Diverter damper maintenance and repair

20. Emissions Reduction – NOx and CO
• Retrofit emissions reduction systems:
• CO Catalyst Solutions
• Exhaust CO Catalyst Solutions (Oxidation Catalyst)
• Integrated within Cullum’s Normal Exhaust Systems in Open Cycle or Combined Cycle arrangements.
• SCR Catalyst Solutions
• Exhaust SCR (Selective Catalytic Reduction) for NOx control & also a CO Catalyst
• Integrated within Cullum’s Exhaust Systems in Open Cycle or Combined Cycle arrangements.
• Spare catalyst blocks including removal and installation service

21. Access Equipment, Mechanical Handling &
Support Steelwork
• Maintenance, repair and modifications of access equipment (ladders, stairways
and platforms)
• Including permanent installations and temporary access solutions
• Steelwork modifications, additions and repairs
• Design to International codes:
• EEMUA
• OSHA

22. Roof System Maintenance
• Roof maintenance
• Buildings
• Equipment
• Electrical switch rooms
• Roofing systems
• Liquid membrane systems
• Multi-layered systems
• Fire retardant systems

23. Lagging and Cladding
• Lagging and cladding systems including
maintenance and repair, including:
• Building systems
• Thermal retention
• Acoustic performance
• Broad range of materials
• Galvanised
• Aluminium
• Stainless steel – 304/316
• Texturized products

24. Thermal Imaging
• Thermal Imaging surveys of operational
equipment including:
• Electrical equipment
• Exhaust systems
• Defining insulation degradation and identify
repair locations

25. 3D Laser Scanning
• 3D site scanning services for
existing installations
• Offered as a stand-alone
service
• Offered within a specific
project work scope

26. Supply of Spare Parts
• Spares to support continuous equipment running
• Spare parts for Cullum and Third Party Installations
• Insurance spaces review to protect against breakdowns
• All types of equipment can be supported
• Reverse engineered if required
• Improved performance can be offered for many parts
• Hazardous area compliance and certification

27. General Site Maintenance and Repair
• General site maintenance operations including full site management and CDM compliance
• Covering all site based disciplines
• Mechanical ducting, piping, weld repairs, NDT services
• Electrical testing, replacement of wiring and devices
• Civil works including building services, concrete repairs and foundation design and site works
• Contract services including corrosion repairs, painting and re-roofing
Resin and Painted floors Armco barrier installation Roof repairs and edge protection

28. Cullum Fabrication Services
• History and Approvals:
• Established manufacturing in 1974 in Heanor,
Derbyshire
• Factory capacity of 26,000 m2
• ISO 9001/14001/18001 accreditation
• Stand alone business unit
• Manufacturing in-house and sub-contract work
scopes
• Approvals for major end users
• Supporting all business sectors
• Energy, Rail, Automotive, Aerospace
• Oil & gas, Defence, Nuclear and Infrastructure

29. Cullum Fabrication Services
• Our People: “The key to our success”
• Support team dedicated to supporting our customers
• Manufacturing engineering
• Listing and production of BoM
• Product Development
• Available man hours (standard working pattern) 42,000 hours, with
ability to work flexible shift patterns (overtime and nightshift working)
• Fabrication Team
• Machine Shop team
• Full range of pre & post machining operations with vertical and
horizontal capacities
• Assemblers and dispatch
• Built in Quality at every stage of the process
• DFM reviews and associated drawing updates and changes

30. Lifetime Care & Product Support
High Integrity Solutions

31. Hot Bolt – Exhaust Flange Bolting System
Extended Life - HotBolt™
• Self-aligning bolt for use on:
• Exhaust Duct flanges.
• Exhaust Collector flanges.
• Expansion bellows.
• Distorted flanges.
• Flanges out of parallelism.
• Flare Stack Flanges/Systems
• Steel structures exposed to thermal
cycles.
• Steel structures exposed to temperature
gradients
• Special designed for high temperature application.
• Special designed for thermal cycles.
• Self-aligning bolt for use on non-parallel flanges.
• Designed not loosen if exposed to transverse
vibrations.
• Designed to not yield when exposed to thermal
growth and temperature gradients in bolted
material.
• Material selection:
• Alloy 800HT
• Inconel 718
• Inconel 625

32. Gas Turbine Exhaust System Expansion Joints
• Design basics:
• Up to 140 m/s gas velocity.
• 12mm thick flanges.
• Increased material thickness in guide plates.
• Machined, double curved corners.
• All steel parts in Chrom-Nickel Alloy
• Special multi layer composite materials in Soft Parts.
• Designed for HotBolt™ flange bolt.
• Designed to fit any installation.
• 20 year design life and 4 year operational guarantee.

33. CCRM™ - Cold Crack Repair Method
• Crack damages to turbine exhaust systems is a severe problem.
• CCRM™ repair concept may extend the life of a crack damaged exhaust systems with more than 500 start/stop
cycles.
• The repair is made without use of hot work, and within a limited time frame.

34. Scanning inside a the Exhaust Duct
Verification by FEM-Analysis
CCRM™ - Cold Crack Repair Method

35. Manufacturing:
CCRM™ - Cold Crack Repair Method
4 axes machining Machined casing, ready for field
installation
CCRM Repair to an LM2500 Hot Exhaust
Collector

36. LM2500 Base and LM2500+4G
Exhaust Collector Repair Kit - Hot Casing Design
• Exhaust Collector Issues:
• After a limited time of operation and number of Start / Stop
cycles, cracks has been observed in the following areas:
• Collector casing corners.
• Collector top flange.
• Collector mounting lugs.
• Collector access cover and cover frame.
• Collector Flange Bolts can relax, causing exhaust leakages into
the Turbine Enclosure.

37. LM2500 Base and LM2500+4G
Exhaust Collector Repair Kit - Hot Casing Design
• Proposed Solution:
• As an alternative to replacing the damaged Collector, or to bring the Collector out of the
Package for repair or replacement, we can offer a Collector Repair Kit.
• The Repair Kit is based on our patented concept CCRM™ (Cold Crack Repair Method).
• The method includes 3D-scanning of the Collector, with Micro Laser Scanner.
• Based on scan point clouds, CCRM Reinforcement Structures are machined to an exact fit
to the crack damaged area.
• Field installation of the CCRM™ reinforcement structures is made in days rather than
weeks.
• No field hot work is needed.
• FEM analyses indicates that the Collector life may be extended with more than 10 years
of operation, and 250+ start / stop cycles.

38. Damage to Collector Wall Lining.
Damage to Collector Cone Lining.
Damage to Collector Wall Thermal Insulation.
• Enclosure over temperature issues and trips
• Damage to instrumentation and cables.
• Ejected from the stack – major safey issue.
• Damage turbine parts
PGT25 Exhaust Collector
Internal Lining and Insulation Kits
• Operational damage to PGT25 Exhaust Collectors internal lining and insulation system
• Experience of Collector Inner Lining and Internal Insulation damaged after long term operation.
• Typical damage:
• Cracking of Inner Lining.
• Parts of the Inner Lining loosen.
• Internal Insulation is degraded and disperses into the gas flow.

39. Wall Lining Corner LiningCone Lining
PGT25 Exhaust Collector
Internal Lining and Insulation Kits
• Internal Lining & Installation PGT25 Lining Kit.
• Prefabricated panels and insulation, ready for
direct installation in Collector Upper Half
Walls and Cone.
• Material selection: AISI 321 or Alloy 800H.
• Installed 12 operational units between 2009
and 2016
• No reports of further damage

40. Air-Oil Separator/Oil Mist Eliminator
• Air-Oil Separator / Oil Mist Elimination
• Removes up to 99.97 % of oil droplets down to 0,2 micron.
• Reduces oil mist to less than 1 ppm.
• Benefits:
• Increased gas turbine efficiency
• Reduced turbine oil consumption
• Improved and safer work environment for personnel
• Patented Air Oil Separators for high speed rotating equipment:
• Gas turbines
• Steam turbines
• Compressors

41. Project Case Studies

42. Onshore – Supply, Installation & Life Time Care
• Project
• Wooler Gas Compressor Station
• Engine
• GE Oil & Gas - 2 x PGT25+ (LM2500+)
• Scope
• Complete Gas Turbine Acoustic & Filtration
Package
• Acoustic Enclosures with Ventilation System
• Support Steelwork Structure & Access
Equipment
• Full Mechanical and Electrical Site Installation
• Life-time care

43. • Project
• St Fergus Compressor Station
• Engine
• Rolls-Royce –RB211 (SGT-A35)
• Scope
• Full design, manufacture and installation of:
• Renewal of complete GT & Compressor
Enclosure
• New Exhaust System
• New filtered cab ventilation system
• New enclosure ventilation intake and
exhaust system
Onshore – Retrofit and Refurbishment
Acoustic Building, Exhaust System and Vent

44. Onshore – Retrofit and Refurbishment
Replacement Air Filter, Combustion Intake and Vent System
• Project
• 3 x SGT-200 - Replacement Intake and Vent
Systems
• Customer
• GNI
• Scope
• Design, manufacture and install:
• Complete Pulse Clean Filter System
• Includes roller shutter
• Dehumidifier
• Combustion intake silencer and ducting
• Complete ventilation system

45. Onshore – Retrofit and Refurbishment
Emissions Reduction Project
• Project
• 2 x Avon Compressor Packages
• Gas Turbine Exhaust Retrofit Programme
• Customer
• National Grid
•
• Scope
• Full design, manufacture and installation of:
• Complete Combustion Exhaust System
• CO Catalyst System
• Replacement Steelwork Structure Access Platforms
• CEMS System
• All site civil works
• Full Site Installation Service
• Commissioning

46. Offshore Tyra West
Exhaust Stack Replacement
• Project
• 2 x LM2500 Exhaust Stacks for Tyra West Platform
– Offshore Denmark
• Customer
• Maersk Olie Og Gas AS
• Scope
• Replacement of 2 x LM2500 Gas Turbine Exhaust
Systems
• Designed to integrate with the existing platform
structure and offshore lifting capacity
• Site installation supervision

47. How can we support you?

48. Contact Details
Mark George
Sales & Business Development Director
mark.george@cullum.co.uk
Tel: +44 (0)1773 544030
Mobile/Cell: +44 (0)7818 456 798
Stuart Foweather
Aftersales Manager
stuart.foweather@cullum.co.uk
Tel: +44 (0)1773 544063
Mobile/Cell: +44 (0) 7798 807467