Optimizing your hydro power plant

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1 Optimizing your hydro power plant

2 A history of engineering excellence With over 180 years of engineering excellence, Wärtsilä is a global leader in advanced technologies and complete lifecycle solutions within the marine and energy market. With an emphasis on sustainable innovation and total efficiency, Wärtsilä aims to maximize the environmental and economic performance of installations for its customers. With widespread market experience, Wärtsilä has extensive engineering capabilities with a global customer base. This has enabled us to develop our expertise in the research, creation and development of custom solutions for renewable power generation and industrial applications. Our history in hydropower Wärtsilä Canada (QuantiServ) specialize in the Hydro and Industrial Services segment. We are a remanufacturer, supplier and installer of hydro-turbines, pumps, seals, bearings and complementary equipment for the hydroelectric and water distribution industries. This provides a comprehensive offering of high quality products and consultancy services for our customers. As an independent, full service provider for hydro applications worldwide, we are fully equipped to support complete lifecycle solutions. Our workshops located in Vancouver, British Columbia and Montreal, Quebec, provide customers with efficient, economical repairs and refurbishment of hydroelectric power plant components. This includes turbine shafts and thrust collars, PRV and TIV valves, runners and all types of Babbitt bearings. Our facility is ISO 9001 and certified, which ensures our quality, safety and environmental protocols are of the highest standards. We also receive the support of accredited third party inspections which helps verify the work completed, enabling us to perform our tasks efficiently and safely. 2 3

3 Complete hydropower solutions With an integrated service offering, we are well positioned to address the need for energy efficient, innovative and flexible solutions. Whether you are looking for enhanced product performance, refurbishment or total lifecycle services, Wärtsilä is here to help. Engineering and project analysis We provide engineered solutions for the rehabilitation of your hydro power plant assets. Our engineers can perform technical inspections on key components and provide technical support to maximize the operational lifecycle of your hydro power plant. On occasion, we receive parts that do not have drawings. As part of our commitment to provide customers with a value added service, we have developed reverse engineering services. Utilizing our digital coordinate measurement technology, together with years of experience in interpreting and creating manufacturing drawings, we are able to refurbish the original part or reproduce replacement parts in a timely and cost-effective manner. Our reverse engineering services utilize advanced measuring technology and the latest AutoCAD applications. After the new CAD model has been created, modifications can also be implemented and 2D blueprints created for production. Upgrades and refurbishment Our engineers are trained and experienced to fully optimize your generating capacity by providing full and in-situ machining and refurbishment of all embedded components to ensure a long-lasting solution. Our site service facilities are equipped to perform activities including Babbitt bearing reconditioning, in-situ and workshop machining and runner cavitation repair. Our upgrade and rehabilitation programmes are tailored to suit your specific needs, helping to create more capacity and efficiency within your hydro plant. 4 5

4 Your global partner in engineered lifecycle solutions Any operational efficiencies you introduce will have a positive financial impact. By choosing Wärtsilä, hydro power plant operators can benefit from a comprehensive service offering, established from skilled expertise and proven technology in the toughest and most demanding applications. We can provide a range of solutions that can be customized to meet your exact requirements. Babbitt bearing reconditioning Occasionally, the condition of a Babbitt bearing can be at risk due to over-heating or lack of lubrication, which requires the part to be re-cast. We specialize in Babbitt bearing reconditioning, particularly segmented guide bearing and thrust bearing components. Other key components routinely reconditioned include turbine shafts, thrust collars and rings, wicket gates, head covers and localized runner repairs (crack and erosion damage). Depending on the bearing s application, we apply a static or centrifugal casting process using only virgin ASTM B-23 Grade 2 Babbitt and CNC machining to very tight tolerances. Once the bearing is recast, we provide bond testing of the Babbitt material to the base metal, which is confirmed by industry standard ultrasonic testing and verified by certified third party inspections. Similar processes and non-destructive testing (NDT) are performed on thrust bearing segments and guide bearing shoes. As part of our quality control processes, we implement a comprehensive inspection regime to prevent defective parts from leaving our site. By integrating digital coordinate measurement technology with traditional quality inspection methods, our technicians have a reliable and efficient way to ensure components meet specific precise specifications and design requirements. 6 7

5 Full service Machining In-situ machining When a damaged component is too large to be transported to a machine shop or involves extensive dismantling work, in-situ machining is a cost-efficient solution. Wärtsilä Canada has developed a revolutionary new generation of centerless in-situ machines. This makes these machines ideal for large diameters, such as the ones typically found on hydro turbines. In comparison to traditional boom-type machines, our centerless solution provides very high precision with the ability to adhere to tight machining tolerances. In addition, a superior surface finish is achieved with higher machining speed, resulting in a cost-effective solution. Line, vertical and horizontal boring Our facilities are equipped with modern CNC vertical and horizontal boring machines for industrial services. Our engineers and machinists are able to handle a wide range of components. In addition to our extensive boring process, we also provide other related services including the repair of worn shafts by welding or metal spraying, machining of key ways, skimming of landing surfaces, reaming of bores including those for shaft line coupling bolts and in-situ honing of inner and outer diameters. As there is a limited supply of boring and facing machines of a versatile, accurate and efficient purpose in the marketplace, we design and build them ourselves. These tools are very advanced and compact, which reduces freight costs and allow our team to work in very tight places. Metal stitching When dealing with casting defects and cracks, we incorporate metal stitching or cold pinning operations. This cold repair method can either be done in a field or workshop environment. This method ensures no additional stresses, which over time may lead to new cracks introduced into the material. In addition, this approach assists to distribute tensile stresses over a large area. With usually little or no dismantling required, the original alignments of parts can be retained as there is no deformation or blemish due to the application of heat. Welding If a large component, such as a runner or a head cover is cracked or damaged, a simple replacement may not necessarily be the best course of action. Often, a replacement part is not available immediately but has to be specially manufactured. This can be time-consuming and costly. In addition, a lot of dismantling and rigging may be required, resulting in the equipment being out of operation for extended periods of time. Wärtsilä Canada specialize in the repair of broken machinery components. Our welding engineers are equipped to support a variety of welding jobs in a power station. This includes repair work as well as fabrication and installation jobs. We can perform most types of welding and metal spray including Stick, MIG, TIG, Flux core, submerged arc, HVOF and twin arc methods. In addition, we also provide post-welding treatment in-house. 8 9

6 Services Refurbishment Our experienced engineers are able to provide hydropower component refurbishments. This covers a variety of components including: Turbine shafts and thrust collars PRV valves Runners Turbine and generator Babbitt bearings Thrust bearings segments. In collaboration with trusted partners, we have designed and modified components including rehabilitation of turbine components. This has contributed towards enhanced reliability and reduced lifecycle costs. Project management We have project management expertise to carry out surveys and inspections, prepare repair proposals, create engineering drawings and refurbish components, including site machining of embedded components, to ensure critical alignments and tolerances are achieved. Our approach to project management begins with preparing inspection and test plans under the supervision of our Engineering department, identifying all witness and hold points along with the type of NDE requirements and final inspections. We provide customers with a detailed project schedule of key activities, milestones and deliverables, in which regular updates are provided through our dedicated team. Remanufacturing capabilities Our manufacturing sites are designed to produce and refurbish high quality turbine components efficiently through our expertise in computer and manufacturing integration. This enables us to produce engineered designs that are input directly into our work centers, which provide a range of manufacturing and machining capabilities. All of our facilities are certified to ISO 9001 and ISO 14001, demonstrating our focus on the quality of refurbishment, safety and the environment. Our in-situ and workshop capabilities for turbine components include: Reverse engineering Full service machining large capacity CNC to facilitate horizontal and vertical boring, milling and turning. Supported by quality control station with digital coordinate measurement technology Centrifugal and static Babbitt casting Shaft seals bespoke design, manufacture and installation Runner repair unit alignment, refurbishment and cavitation repair Blades cavitation repair and restoration of blade profile Discharge ring extension and embedment cavitation repair service Stay ring and guide vane modifications or replacement Valve/pump/actuator/control links overhaul removal, refurbishment and re-installation services Packing gland and lantern ring fabrication Welding and fabrication services Stress relieving and sand blasting services Coatings and pump reconditioning Static and Dynamic Balancing HVOF spray welding

7 Total lifecycle solutions With over a century of engineering experience, Wärtsilä is ideally placed to help you with your hydropower needs. Our vast portfolio, global capabilities and refurbishment centers offer cost-effective environmentally friendly ways to harness the power of hydro. Contact For more information, please contact us on hydroandindustrialservices@wartsila.com Follow us on WÄRTSILÄ is a registered trademark. QuantiServ is a registered trade name of WÄRTSILÄ. AutoCAD is a registered trade name. Copyright 2018 Wärtsilä Corporation. Specifications are subject to change without prior notice. Printed