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C&K Overview Presentation - 6

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C&K Overview Presentation - 6

  1. 1. • MAIN PLANT: 150,000 FT2 • 250 SKILLED EMPLOYEES • 2 PERMANENT SHIFTS • SERVICE 24/7, 365 DAYS • 22 OVERHEAD CRANES • MAX CRANE CAPACITY: 65 TONS • FIELD & OUTAGE SUPPORT Chalmers & Kubeck, Inc. ISO 9001:2008 & 10CFR50 Appendix B / NQA-1 2008/09 NR Certificate of Authorization (Stamp # 105) • CNC MANUFACTURING • GEAR SERVICES • ROTATING EQUIPMENT & FIELD MACHINING • WELDING & FABRICATION • ENGINEERED PUMPS • THERMAL SPRAY & GRINDING • VALVE SALES & SERVICE
  2. 2. Prominent Member of the AGMA Precision Gear Manufacturing up to 2M Diameter (74”) Spur, Helical, and Double Helical Gears GEAR SERVICES
  3. 3. Internal Form Grinding Spur & Helical Gear Sets Probe Checking Gear Tooth Geometry
  4. 4. Gearbox Repair Gear Tooth Contact Pattern
  5. 5. Planetary Gear Box Re-Build
  6. 6. Custom Gear Drives: Reverse Engineered, Upgraded, Fabricated, Machined & Assembled
  7. 7. Tube Reduction Saddle Reverse Engineered, Upgraded Components, Fabricated, Machined & Assembled
  8. 8. Custom Gear Drive Housing Reverse Engineered, Upgraded Design, Built & Tested
  9. 9. Table Drive and Shear Drive Re-Build
  10. 10. Pickle Line Re-Coiler Complete Package Overhaul
  11. 11. Safety Related Gear Drives  High Pressure Coolant Injection  Charging Pump  Cooling Tower  Traveling Screen
  12. 12. Circulation Water Traveling Screen • Repair / Replace Screen Baskets • Linkages, Pins, and Composite Bushings • Head Shaft, Sprockets, and Tensioners • New S.S. Piping w/ Hydro Test
  13. 13. Gear Field Services: Repair, Machining & Maintenance  Removal & Installation  Complete Overhauls  Laser Alignments  Bore Scope Inspections  Vibration Analysis  Technical Assistance
  14. 14. Field Machining Services • Bearing Journal Sleeve Repair • 24” max dia. • Boring / Turning • 50” max dia. • Drilling / Tapping • Studs up to 5” dia. • Facing • 50” dia. (in house) / 120” dia. (rental) • Heat Exchanger Repair • Resurfacing of Tube Sheet /Shell • & Division Plates • Milling • Machine Base Milling 48” x 120” • Keyway Relocating, Enlarging & Repair • Turn-Key Services • Vibration Analysis, Equipment Removal & Repair, Equipment Installation, Alignment, Balancing • Valve Repairs • Hard Face Removal, Weld Build-up & Seat Angle Machining
  15. 15. Air Powered CLIMAX MODULATHE Boring / Facing Machine
  16. 16. 24” Capacity SILK ID Mount Flange Facing Machine
  17. 17. 2” Hydraulically Powered Line Bore Machine – Pump Casing
  18. 18. DL-RICCI 8” OD Mounted Journal Lathe
  19. 19. 4’ DL-RICCI Milling Machine
  20. 20. OD Mount Clam-Shell Pipe Cut & Weld Prep Machine Capability up to 16” diameter
  21. 21. Gas Turbine Burner Repair Weld, NDE & Machining
  22. 22. Turbine Blade Assembly & Tip Grinding
  23. 23. Diaphragm: Wet Magnetic Particle Inspection, Re-vane, and Assembly
  24. 24. Turbine Overhauls - Elliott - Terry - Murray
  25. 25. Turbine Shaft Chrome Oxide (Plasma) Carbon Seal Area Tungsten Carbide, 17% Cobalt (HVOF) Bearing Journal
  26. 26. SCHENCK Balancing up to 5,000 lbs.
  27. 27. Fabrication & CNC Machining Double Decker Hydrogen Collector Blower
  28. 28. Faro Edge CMM Arm with Laser Scanner Dimensional Verification & Replication
  29. 29. Faro Ion Laser Tracker Setup, Dimensional Verification, and Layout Accuracy .0004” In-Line @ 8m .0009” Horizontal Scale Bar @ 2m .00019 Horizontal Scale Bar @ 10m
  30. 30. Cable Drum - Precision Ball Milling
  31. 31. Fly Cutting w/ Right Angle Head – Horizontal Mill Small Fabrications and Custom Manufacturing Solutions
  32. 32. Air Bearing
  33. 33. Blade Ring 5” Scale
  34. 34. Welding Certifications  National Board NR Certificate of Authorization  National Board Repair (R Stamp)  ASME Section IX Certified Welders  ASME U and PP Stamp Certified  ASME B31.1 and 31.3
  35. 35. Turbine Stop Valve Seat Finish Machining Stellite Hard Facing
  36. 36. Large Vessel Fabrication & Welding
  37. 37. STRONGBACK Fabrication & Machining
  38. 38. Nuclear Waste Storage Cask Fabrication & Machining (41 Tons – Crane Capacity 65 T) Large CNC Horizontal Milling Max 30’ Long & 14.5’ High
  39. 39. Large CNC Vertical Turning Max 32’ Diameter & 10.5’ High
  40. 40. Condensate Pump Motor Stand Machining Gray VBM: Twin Head Table – 14’ Height – 12’ 9” (Under Tool)
  41. 41. Large Shaft Refurbishment Up to 30’ Long w/ 91.5” Swing Over Ways
  42. 42. Engineered Pumps
  43. 43. High Speed Barrel Style Pump Running Clearances, Straightness & Fits Restored to O.E.M. Specifications
  44. 44. Pump Casing Line Bore
  45. 45. Pump Case Restoration Brazing, Inserts, and Machining
  46. 46. Goulds Pump Naval Bronze Restoration Bearing & Case Ring Fits Worn / Pitted Thermal Spray Repair, Split Face Machined, and Line Bored
  47. 47. Thermal Spray Repair Using Aluminum Bronze Circulating Water Impeller Restoration
  48. 48. Pump Discharge Head Reverse Engineering, Fabrication, Machining & Assembly
  49. 49. Circulating Pump Overhaul
  50. 50. Circulating Pump – 84” Worthington Hi-Flow
  51. 51. Service Water Pump
  52. 52. Heater Drain Pump
  53. 53. Barrel Style High Speed Feed Pump Complete Turn Key Field Service
  54. 54. 5 Relief Valve Test Stations Steam – 1,500 psi ● Air – 3,000 psi ● Hydrostatic – 10,000 psi • Valve Plant: 27,000 ft2 • Service 24/7, 365 • Field & Outage Support • 9 East Coast Service Centers Chalmers & Kubeck, Inc. ISO 9001:2008 & 10CFR50 Appendix B / NQA-1 2008/09 NR Certificate of Authorization (Stamp # 105)
  55. 55. Largest East Coast Consolidated (G.E.) PSV Commercial Stocking Distributor – BOP Only Stamps: “VR”, “NR-VR”, “V”, & “UV”
  56. 56. Hydrostatic Testing Line Valve or Mechanical Equipment Max 20,000 psi
  57. 57. Limitorque Blue Ribbon Facility Factory Authorized Service Center Largest East Coast Limitorque Master Distributor Expert BOP Sales, Service, and Field Support
  58. 58. Thermal Spray 101 • What is Thermal Spray • What is it Used For • Typical Industrial Applications • Coating Deposition Methods • Process & Coating Characteristics
  59. 59. Thermal Spray 101 What is Thermal Spray?
  60. 60. Thermal Spray 101  Surface Restoration  Service Induced Wear  Manufacturing Errors  Protective Coating  Fretting and/or Wear  Galling  Erosion  Corrosion  Oxidation / Hot Corrosion What is it Used For? Example of Thermal Spray Reclamation / Dimensional Restoration
  61. 61. Thermal Spray 101  Babbitt Bearings  Bronze & Iron Casting Repair  Hard Chrome Alternative  Hydraulic Rams and Pistons  Pipe Elbow I.D.s  Roll Resurfacing  Rotating Equipment  Shafts, Shaft Sleeves & Coupling I.D.  Bearing Journals & Seal Diameters  Housing & Stuffing Box Bores  Case & Wear Rings  Blowers, Fans, Impellers & Turbines  Strainers  Valves  Gates & Balls  Seats, Stems, and Trim Sets  Spring Aluminizing HVOF Tungsten Carbide Coating of a Piston Rod Typical Industrial Applications
  62. 62. Thermal Spray 101 Deposition Methods  Flame Spray  Babbitt and low temp anti-corrosion  Electric Arc Spray  Predominately Metal Coatings  High Velocity Oxygen Fuel (HVOF)  Premier method for Carbide application  Atmospheric Plasma Spray (APS)  Premier method for Ceramic application Kinetic Energy (Left to Right) Thermal Energy (Bottom to Top)
  63. 63. Thermal Spray 101 Deposition Method: Electric Arc Wire Spray  Electric Energy  Wire Feed Stock  Predominantly Metallic Coatings  Cored Wires allow Advanced Material Compositions  Most Economical Surface Restoration Process  Versatile and Simple  High Deposition Rates  Machine Finish  Readily Portable
  64. 64. Thermal Spray 101 Deposition Method: High Velocity Oxygen Fuel (HVOF)  A high pressure combustion “flame” heats and propels the powder particles.  Extremely high particle velocities: 3,300-3,900 FPS – Supersonic! (JP-5000/8000)  Very dense coatings – porosity <1%  Highest Bond strengths of Carbide and M-CrAlY type coatings  Tests exceed the strength of the epoxy (> 10,000 PSI) F-35 X-45
  65. 65. Thermal Spray 101 Deposition Method: Atmospheric Plasma Spray  Powder Feedstock  Plasma energy produced from high intensity arc + plasma forming gases: Ar, He, H, N, or combinations  Highest thermal energy of all the thermal spray processes (~17,000 ○F) and is the optimal method for application of ceramics & ceramic-metal cermets.  Most versatile deposition process and well suited to spraying I.Ds.
  66. 66. Thermal Spray 101  Application process is line-of- sight. Spraying of Internal diameters is possible using a special I.D. gun or by using an angled spray technique (limited).  Unlike a fusion weld, the method of sprayed particle adhesion is generally mechanical; surface preparation is critical.  Dissimilar materials can be joined – a HP coating can be placed on an inexpensive base material!  The minimal heat input does not distort the base material like welding!  While the coatings do not add mechanical strength, they are generally more wear resistant than the same material in wrought or cast form. With a HP coating, it’s possible to increase functional service life up to 3x!  Coatings must be sealed for the intended application. General Process & Coating Characteristics
  67. 67. Hydraulic Ram Refurbishment • Thermal Spray Repair – Electric Arc Spray w/ 400 series Stainless Steel • Finish Grinding
  68. 68. Pump Shaft Sleeves Dimensional Restoration & Protective Coatings  Left:  Large Sleeve: New, Monel w/ Cr2O3-SiO2TiO2  Small Sleeve: Nitronic-50, w/ Bond Coat, Hard Stainless Overlay, and Tungsten Carbide Protective Coating.  Right:  Large Chrome Oxide Sleeves Installed
  69. 69. Worthington 2-Stage Heater Drain Pump  PROBLEM: Between 1990 and 2005, there were 9 seal failures requiring rebuild and 2 bearing failures due to water intrusion from seal failures.  SOLUTION: Engineering developed a mod package in conjunction with C&K to upgrade the intermediate bushing to a non-galling composite that would stabilize shaft dynamics. C&K provided on-site supervision during the pump / seal assembly.  RESULTS: Since the implementation of these changes, there have been NO SEAL FAILURES on the associated pump resulting in an approximate cost avoidance of > $97,000.  Seal Rebuild Kits: $7K  Planning & Maintenance costs per seal rebuild: $15K.  Above costs do not include OPS, RP, Work MGT, etc.
  70. 70. PROBLEM: Service Water Stuffing Box Sleeve - Wear  Equipment: Four Vertical Turbine Pumps  Johnston on Unit 1 & Fairbanks-Morse on Unit 2  Problem: Premature wear on stainless steel stuffing box shaft sleeves.  Leaks and excessive maintenance.  Max service life only 11 – 13 months before sleeves required replacement!  Cause: River silt coupled with obsolete pump packing effectively ground away the relatively soft sleeves.
  71. 71. SOLUTION: Service Water Stuffing Box Sleeve - Upgrade  Solution:  New shaft sleeves manufactured by C&K and coated w/ Plasma application of Chromium Oxide  Softer Garlock packing material  Results:  Shaft Sleeve hardness increased from ~28Rc to ~70Rc  The Utility Engineer classified this as a success story within 2 months due to significantly reduced maintenance.  Customer inspection after one year revealed no sleeve degradation whatsoever. Pump returned to service with simple packing change-out. Upgraded Shaft Sleeves with Chrome Oxide Coating
  72. 72. Circulating Water Strainer - Cone Significant wear and erosion around tapered O-Ring groove area – 316L S.S. O-Ring groove area restored and then upgraded with HVOF Tungsten Carbide coating for particle wear resistance – 64 Rc
  73. 73. Circulating Water Strainer- Body Wear groove from strainer cone sealing gasket (0.160”) – 316L S.S. Tapered seal area restored using Alloy 400 (Monel) for marine corrosion resistance.
  74. 74. Service Water Strainer - Shaft Strainer shaft packing area worn (0.180” deep) – “obsolete” flame spray coating Strainer shaft packing area restored and upgraded with a plasma applied chromium oxide ceramic (69-75 Rc)
  75. 75. 20” Service Water Strainer - Cone C&K restored the O-Ring groove using Aluminum Bronze Thermal Spray in 3 Weeks at a fraction of the OEM replacement cost
  76. 76. Service Water Strainer – Body Field Repair & Machining – Cast Bronze  Problem:  Strainer Body > $300,000 to purchase new  Removal / re- installation ~$350,000  Welding not possible  Solution:  Strainer Body Thermal Spray repaired at customers’ site with Aluminum Bronze using C&K machine tool designed and built for this application.
  77. 77. Circulating Pump Bearings & Shaft PROBLEM  Problem: Premature bearing wear, shaft wear, and greater than desirable vibration levels.  Cutlass Rubber Bearing required replacement after 1.5 - 2 years  Worn bearing would result in increased pump vibration  Pump Shaft Journals were being worn away by abrasive media  Cause: Cutlass Rubber bearing material trapped sand/silt and effectively ground away the pump shaft.
  78. 78. Circulating Pump Bearings & Shaft SOLUTION  Solution:  Pump shaft journals coated by C&K w/ Plasma applied Chromium Oxide Ceramic  Green Tweed AR1 composite bearing installed w/ reduced running clearances  Results:  Lowest vibration level of the customer’s mixed flow vertical pumps!  Bearing & Shaft service life increased 3x after the upgrade with anticipated 4x (9 years overhaul target) – that’s a huge ROI Cutlass Rubber Bearing Green Tweed AR-1 Bearing
  79. 79. Pump Shaft Sleeves Dimensional Restoration & Protective Coatings  Left: Large Sleeve (New): Monel w/ Chromium Oxide Ceramic Coating Small Sleeve (Repaired): Nitronic-50, w/ Bond Coat, Hard Stainless Overlay, and Tungsten Carbide Coating  Right: Large Chrome Oxide Sleeves Installed
  80. 80. Customer Involvement  CASE WEAR RINGS – upgraded from Nitronics 60 to Greene Tweed composite  IMPELLER WEAR RINGS, STUFFING BOX & SHAFT SLEEVE – restored dimensions and upgraded w/ Chromium Oxide  FEMALE COLUMN FITS, IMPELLER BOWLS & BORES – restored using hard stainless thermal spray  LINE COUPLINGS – thermal sprayed IDs with hard stainless as anti-galling to aid in subsequent disassembly 3-Stage Service Water Pump OVERHAUL
  81. 81. Feedwater Pump Breakdown Bushing & Shaft PROBLEM  Equipment: WGID Pump, 375 ◦F Treated Water  Problem: Common failure upon start-up - the 410 S.S. pump shaft would contact the 410 S.S. breakdown bushing (labyrinth design) resulting in galling and pump seizure.  Cause: Temperature stratification during start-up would distort pump case in relation to shaft resulting in the loss of the original running clearances; the pump would seize.
  82. 82. Feed Water Pump Breakdown Bushing & Shaft SOLUTION  Solution:  Pump sleeve coated by C&K w/ Plasma application of Chromium Oxide (Cr2O3-SiO2-TiO2) opposite bushing area  Green Tweed WR525 thermoplastic composite bushing with non- labyrinth design installed with reduce running clearances.  Results:  Upgraded breakdown bushing with protective chromium oxide coating on pump sleeve achieved same pressure reduction of original labyrinth seal without galling / seizing or shaft damage. The upgraded configuration functions almost like another bearing!  Upgraded design has been functioning for over 6 years with expected 7.5 – 9 years before service required.
  83. 83. Station Air Heat Exchangers  Problem: MIC damage to 316 S.S. tube sheet faces.  Solution: Wetted face area repaired and upgraded with a Hastalloy C thermal spray coating at a small fraction of the replacement cost.

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