Excellent Engineering Solutions
Introduction to The Weir Group Weir is a FTSE100 global engineering solutions provider focused on the minerals, oil and gas and power markets. The Group designs, manufactures and provides aftermarket support and services for pump and flow control products, with market leadership positions in a number of product areas. Weir operates in more than 70 countries and employs over 14,000 people. Health & Safety Employee health and safety is of paramount importance to The Weir Group. The Group is committed to zero accident workplaces. To ensure this we have introduced the Weir Environment, Health and Safety (EHS) System. The Weir EHS system sets out global standards for areas including behavioural safety, operational control of risk, fire and environment. The Group s policy is that all its operations aim to achieve OHSAS 18001 (Occupational Health and Safety Assessment Series) accreditation. Find out more about The Weir Group at www.weir.co.uk 2
Weir Engineering Services Sitting within the Power & Industrial division of The Weir Group, Weir Engineering Services provides a wide range of services aimed at optimising the long term operating environment of plants and facilities, bringing increased performance efficiencies and lower lifetime costs. The Weir service portfolio includes: Pump services Valve & Actuator services Turbomachinery services Advanced Part Solutions Specialist Coatings services Hydro-Electric Power services Wind Power services Plant Rehabilitation services Allen Steam Turbines Weir s services are applicable to a diverse base of power, industrial and oil & gas facilities such as: Nuclear power stations Thermal power stations Hydro power stations Geothermal power stations Waste-to-energy and biomass power stations Wind farms Oil & gas production facilities Refineries and petrochemical plants General industrial plants Water treatment and pumping stations Wind power. Nuclear power. Thermal power. Hydro power. Refining. Oil & gas production. Waste-to-Energy. Industrial process. 3
Maximised pump efficiency and extended life Pump Services Weir is synonymous with world-leading pumps and our vast OEM knowledge and engineering skills enable us to provide a complete service for the repair, overhaul and upgrade of both Weir and non-weir pumps. These services are delivered on-site and in specialised workshops and cover a comprehensive application range. Workshop pump overhaul. Winding of a 1000kW submersible motor. Roto-Jet pump supply and service. Complete maintenance programs covering standard service to refurbishment with repairs including welding and re-machining Full range of testing capabilities to identify performance and condition issues (including noise, vibration and thermometric efficiency) Advanced Part Solutions providing re-engineered and manufactured parts including performance and material upgrades Specialist coatings to protect against corrosion, erosion and cavitation and to enhance fluid flow Services for mechanical seals from refurbishment, upgrades and managed service exchange to supply of new seals Complete service for the manufacture, repair and overhaul of submersible wet wound pumpsets and electric motors Supply of the complete range of Roto-Jet high pressure pitot tube pumps as well as spares Spare parts supply from stock All legacy Weir branded pumps and current brands Pumps from any manufacturer covering typical applications such as: feedwater, booster, boiler circulating, condensate extraction, cooling water, fuel/ lube oil, drain, seawater lift Pump categories: horizontal and vertical split case, submersible and vertical split case, submersible and immersible, axial and mixed flow, multistage Lower total cost of ownership through increased mean time between failure and reduced unscheduled maintenance Full knowledge of issues and options to inform decision making for best case resolution Return to existing state or improved state based on repair or upgrade work to your specification Optimised pump performance to meet process conditions and extended lifespan of equipment Reduced power costs with maximised pump efficiency and extended life of internal parts Improved equipment reliability with repairs and upgrades meeting changed process conditions and HSE requirements Cost savings when avoiding replacement with new Long term pump reliability from high quality manufacture and pre-supply performance testing Return to service with extended lifespan and improved performance through repair and engineered upgrades and re-rates Reliable and efficient pumps OEM spare parts and service support Maximised uptime due to fast response Split case pump under test. pumpservices@weirgroup.com 4
Safe and compliant leak-free valves Valve & Actuator Services As a leading OEM valve supplier across multiple industries, Weir is well positioned to support valves and actuators throughout their operational life. This is delivered through a comprehensive portfolio of maintenance services and specialised engineering solutions enabling effective management of your assets. Outage and shutdown project management and delivery across all valves and controls. Delivered by experienced managers and onsite engineers and backed up by fully equipped workshops Statutory inspections, overhauls and repair of valves and actuators of any manufacturer (including asset management and maintenance planning) In-situ valve seat replacement combining Weir service expertise with leading welding technology Online safety valve testing and analysis (hot and cold/ fast and safe) Operation and service training programs carried out by our valve and controls experts Maintenance programs and OEM parts, upgrade kits and replacements for Hopkinsons / Autotork actuators Specialist Control Valve Services with state-of-theart testing equipment, software and experienced technicians backed by OEM technical expertise Butterfly, gate, globe, check, safety and control valves from Weir or any manufacturer along with associated actuators Controlled delivery from a single source with effective pre-planning and project management Prompt on-time return to service with full HSEQ process compliance throughout Reliable ongoing operation with leak-free valves serviced by experts in valve design and operation Optimised operation of all valves and controls with security of work carried out to certified levels by proven reliable company Ease of management through consolidation of service and maintenance programs under Weir Minimised operational downtime with seat issues resolved without valve removal Cost effective solution avoiding new valve replacement and extending valve lifespan Maximised valve integrity and efficiency avoiding interruption of production Control over standard maintenance activities with personnel trained to Weir s standard Extended lifespan of reliable actuators without costly and time intensive change-outs Reassurance of safe and compliant valves with full test certification Any faults or issues identified along with best resolution options to maximise valve integrity and efficiency from valves returned to service Full HSEQ process control. In-situ welding machine in operation. Dedicated actuator workshop. Simultaneous testing of valve, actuator and controls on specialist equipment. valvesservicing@weirgroup.com 5
Optimised turbine or compressor performance Turbomachinery Services Weir s knowledge of steam turbines and gas compressors is founded on a combination of manufacturing heritage and long-standing service provision. Weir applies this experience to deliver a range of services from inspection and repair through to complex refurbishment projects; all designed to minimise operational cost, extend product life and increase efficiency. Workshop assembly of compressor. Rebladed turbine. Installation of overhauled steam turbine. Inspection and repair services covering compressors, turbines and auxiliary equipment as stand alone project or part of outage Managed refurbishment and enhancement of turbomachinery upgrades and re/de-rates in response to changes in operating conditions product enhancements designed and manufactured to address operational issues Advanced Part Solutions providing re-engineered and manufactured parts including performance and material upgrades Full range of performance tests to deliver best case solutions incorporating: diagnostic analysis and condition assessments noise and vibration analysis conceptual design and performance mapping Specialist coatings to counter corrosion, erosion and cavitation All services delivered using a combination of local capability, field engineers and centre of expertise workshops Gas compressors: all axial, centrifugal and reciprocating models from any manufacturer Steam turbines: all models under 100MW or above if required through alliance partners Supplementary products such as gearboxes, power recovery turbines, blowers, fans and general ancillary equipment Reduced management with Weir as single source provider of all service and repairs Optimised turbine or compressor performance with updated designs to meet current and future process conditions Greater return on investment from existing machines with extension of operable life Minimised downtime through well planned project delivery Extended lifespan of equipment through enhanced material durability Increased performance through components re-engineered to latest standards Alternatives to direct repair or replacement Reduced downtime by identification of issues prior to full shutdown followed by targeted action Full knowledge of issues and options to inform decision making for best case resolution Return to existing state or improved state based on repair or upgrade work to your specification Extended lifespan of equipment and components through enhanced material engineered coatings Minimised downtime and cost with work carried out by best-fit engineers at facilities relevant to your job or project Completed rotor and bundle for gas platform. turbomachinery@weirgroup.com 6
Viable alternatives to OEM supply Advanced Part Solutions Weir has over 20 years experience in the re-engineering and manufacture of component parts and assemblies, ranging from simple machined sleeves through to complete re-engineered machines. Weir s Advanced Part Solutions provides re-engineered and manufactured parts including performance and material upgrades. Weir is able to provide a timely, cost-effective solution when you are faced with potentially long delivery times, high cost or dated OEM options. In some cases the OEM may no longer supply or exist Using the latest technology Weir can obtain an accurate profile of equipment regardless of complexity. Combined with an in-depth understanding of operating conditions and your requirements our design experts can engineer the optimal design in the most appropriate material Newly designed components and equipment benefit from modern manufacturing processes to ensure quality and cost effectiveness. All new parts carry a Weir warranty Management of your entire engineered spares supply requirements. From on-site data collection to on time supply for stock replenishment All Weir work is carried out within a robust reverse engineering policy Full range of service and maintenance options available with current design documentation to support Pumps from any manufacturer covering typical applications such as: feedwater, booster, boiler circulating, condensate extraction, cooling water, fuel/ lube oil, drain, seawater lift Valves: butterfly, gate, globe, check, safety and control Gas compressors: all axial, centrifugal and reciprocating models from any manufacturer Steam turbines: all models under 100MW from any manufacturer Other rotational plant such as mixer arms and blades, fans and blowers Shipping and derrick repairs, casting moulds, damaged special gears and systems Manufacturing process equipment Alternatives to direct repair or replacement Latest materials and techniques used for design and manufacture Quick return to service with short lead times Optimised equipment performance to meet current and future process conditions through components re-engineered to the latest standards Extended lifespan of equipment through enhanced material durability Reliable and durable solutions fit for purpose Reassurance of dealing with a major manufacturer Reduced management effort with single source supplier On time delivery with unique part code assigning for ease of re-order Reassurance of quality controls throughout that are designed to respect third-party intellectual property rights Operational confidence Control over any future component design changes Re-engineered compressor impeller. Precision scanning to build 3D model. Quality component manufacture. 1500mm dia. inner bowl from main cooling water pump. advancedpartsolutions@weirgroup.com 7
Global Capability With a global footprint, Weir has a far reaching capability. A selection of projects across the world is given below. For more information please visit www.weirpowerindustrial.com and for details of what engineering services Weir can offer in your territory, please contact us at servicesinfo@weirgroup.com Waste-to-Energy Plant, Netherlands Supply and installation of Allen Steam Turbines turbo-generator package. Coal & Nuclear Power Plants, Canada Overhaul and replacement of Hopkinsons actuators across multiple sites. Coal & Nuclear Power Plants, UK Full valve outage management and service delivery. Off-Shore Platform, Trinidad & Tobago Compressor overhaul, service support and commissioning of compressor train. Wind Farms, Brazil Electrical and mechanical works and supply and installation of climb assistance equipment. 8
Gas Processing Plant, Iraq Refurbishment of 4 compressor trains (including associated turbines and pumps). Desalination Plant, Kuwait Refurbishment and re-tubing of distillers and overhaul of pumps. Geothermal Power Plant, Philippines Refurbishment project covering pumps, valves, engines and generator. Steel Plant, Libya Rehabilitation of power unit (85MW turbine, generator, pumps and valves including re-engineered parts). Gas Platform, Malaysia Re-rating of 3 gas compressors (including material upgrades). Coal-Fired Power Plant, South Africa In-situ valve seat replacement program. 9
Greater equipment and system resilience Specialist Coatings Services Weir specialises in the application of high performance protective linings and coatings using an extensive portfolio of techniques and products. Combined with our long standing knowledge of operational environments across many industries, our coatings can be relied upon to protect equipment surfaces and enhance systems. Coatings designed to protect equipment, pipework, vessels and structures from the effects of erosion or corrosion caused by water or chemical substances Coatings designed to enhance the flow of fluids through equipment and pipework Weir uses an extensive range of coating products which are carefully selected to best meet the usage requirements and environment Our premium composite ceramic product can even be used to patch and reshape components to protect against extreme abrasion and chemical attack Weir uses specialist SQEP* technicians and a variety of techniques to apply the coating to high standards in quality and process control Services are delivered from dedicated facilities fully equipped for leading preparation and application techniques and through a team of specialised field service engineers. Projects managed to high standards throughout Reduced maintenance and repair costs by extending the time between failures caused by surface wear and corrosion Increased performance of equipment and systems leading to cost saving in terms of the energy required to perform the required tasks Assurance of most appropriate resin or powder coating product selected to meet specific needs by provider who understands products and systems Greater equipment and system resilience resulting in lower maintenance costs and greater operational uptime Assurance of high quality workmanship maximising lifespan of application Delivered on time and on budget with minimised downtime due to experienced management and project team Glass flake lined ECW pipework. Blast surface preparation. Spray coating application to valve. Pumps and rotating equipment Valves and associated control devices Tanks, vessels, storage equipment, large and small bore pipework Metal and concrete structures Epoxy powder coating of split case pump. coatings@weirgroup.com 10 * Suitably Qualified and Experienced Person
Increased revenues through higher generating efficiency Hydro-Electric Power Services Weir offers a world class portfolio of skills in hydro equipment refurbishment developed over more than 50 years. Combining our service experience with in-house design capability from Weir American Hydro and alliance partners, Weir can deliver a comprehensive maintenance, replacement and rehabilitation service. Hydro station refurbishment and rehabilitation projects covering: mechanical installation and overhaul refurbishment and replacement of auxiliary systems generator overhaul new protection and control equipment full project management to installation and commissioning Comprehensive maintenance service packages, covering all mechanical elements of the plant, from call-off contracts to framework agreements Design and supply of high performance runners to upgrade existing systems (including full installation and commissioning service) Specialist coatings for key plant components (including spiral casings and draft tubes, penstocks, valves, guide and stay vanes and tanks) Complete solution from a single source (Weir consortium) providing controlled delivery of project from end-to-end Increased performance through upgrades to critical components and application of system knowledge Increased asset lifespan and reduced requirement for major intervention Reassurance of long term reliable performance and safety Higher levels of uptime due to avoidance of unscheduled interventions and rapid response to emergency issues Increased revenues through higher generating efficiencies from the same water resource through optimised design Increased system performance due to enhanced flow through components Longer component life spans through reduced corrosion and cavitation All main plant components and systems within small to large power stations Runner replacements and upgrade for Francis and Kaplan turbine designs Service engineers onsite. 127 Kaplan runner. Refurbished Pelton turbine. Installation of 110 Francis runner. wesrenewables@weirgroup.com 11
Long term reliable operational success Wind Power Services Weir provides bespoke service and engineered solutions aimed at increasing performance for wind turbine fleets and maximising uptime. Combined with Weir YES, our service offer includes maintenance, refurbishment, management and commissioning of resources. Our services are provided via central hubs using engineering experts and delivered through a network of field engineers. Wind turbine installation services. Onsite inspection and maintenance. Replacement gearbox preparation. Operation and maintenance (including asset management) featuring routine performance monitoring and fault diagnosis End of warranty engineering inspection service Major component repair and refurbishment from removal to refit Gearbox servicing options from standard maintenance and repair to fully managed programs and refurbishment Critical parts supply and installation (OEM parts or re-engineered where required) Construction commissioning and turnkey contracts Products from all major manufacturers: gearbox, rotor, drivetrain, yaw, generator, electrical systems Reduced management complexity through single source service provision Long term operational success with timely interventions and engineered solutions to technical issues Impartial assessment enabling warranty to be fully utilised and reassurance of smooth transition into post-warranty life Minimised downtime with rapid turnaround and quality assured workmanship Performance enhancements from material upgrades Reliable performance and issue avoidance through scheduled maintenance Optimised performance and minimised downtime through bespoke service management and gearbox exchanges Minimised downtime with rapid parts change-outs and return to service Reduced management requirement with Weir handling the whole process Lower cost and/or part life improvements through re-engineering Controlled delivery with effective pre-planning and project management Reliable performance through knowledgeable installation of multiple turbine types and vendors Gearbox during workshop overhaul. wesrenewables@weirgroup.com 12
Maximised operational performance and plant life Plant Rehabilitation Services Weir s plant rehabilitation services are aimed at increasing electrical and industrial power plant performance and extending lifespan. Weir unites its own engineering capabilities with industry leading experts in total system and major component design to ensure best-in-class knowledge can be applied throughout. Complete plant rehabilitation from initial baseline assessments through to supply, overhaul and commissioning In-depth understanding of all issues specific to your plant with experts specialising in the design and operation of each piece of equipment and process Experienced system engineers to ensure each component of the plant integrates successfully in the system Detailed planning and end-to-end support from project managers experienced across power plant maintenance and infrastructure projects Project engineers and managers trained in delivering projects compliant with HSEQ process All equipment and components supplied are manufactured to international standards Minimised management complexity and project risk by dealing with a single team from enquiry to completion Cost effective delivery of whole project Generation capabilities increased and reliable performance across whole plant through bestin-class refurbishment and/or selection of new equipment Optimised solution from fuel input to electrical output meeting the required performance specification and budget Increased revenues due to return to operation on time and budget minimising generation downtime Assurance of project delivery with clear view of progress until handover to your operational team Minimised downtime or projects delayed due to accidents Designed with regulatory environmental compliance considerations Reliable ongoing performance of installed or refurbished equipment Product coverage (with alliance partners): Emission Control, Burners and Pipework Boiler Pressure Part Design and Manufacture Pipework System Design, Installation and Refurbishment Process Control and Instrumentation Pump and Motor Refurbishment Gas Compressor Refurbishment Steam or Hydro Turbine/ Generator Refurbishment Valve and Actuator Refurbishment Propane train refurbishment in Middle East. Initial inspection of coal-fired unit. Work on desalination plant. Refurbished turbine from steel complex. International.projects@weirgroup.com 13
Cost effective solutions maximising efficiency Allen Steam Turbines Through our Allen Steam Turbines brand, Weir offers a proven range of turbine solutions designed to meet the industrial challenges of today s need for power, steam and heat. Suitable for environments requiring back-pressure, condensing and/or steam extraction capabilities, the range includes multi-stage and single-stage models up to 65MW. Turbine package installed in waste-to-energy plant. Multi-stage turbine in production. Turbine with controlled extraction in sugar mill. Flexibility to meet the precise operating conditions for which the machine is intended within standardised frame sizes Custom engineered turbine, skid mounted and with the best generator options available; all sourced and managed using our extensive expertise Weir takes you through the design stages, supporting with application specific advice and keeping your team up-to-date with everything needed to deliver your project successfully Weir engineers are an integral part of your project team; with training of your plant maintenance and operational personnel as required Technically well designed and manufactured product through the modern production capability of our manufacturing partner, NG Metalúrgica Full range of service and maintenance packages to ensure long-term reliability and problem resolution Full turbo-generator package incorporating gearbox, generator, condenser and complete control and protection systems sourced from leading manufacturers and flexible to meet customer requirements Power range up to 65MW; Inlet pressures up to 86 bar; Inlet temperatures up to 520 C Cost effective solutions maximising efficiency of each application Flexible package solution tailored to your needs Single responsible source to deal with Ease of delivery, installation and commissioning on site Assistance given at all stages of the contract Project delivered, commissioned and handed over within schedule Smooth transition into operational life and in-house team able to take over control Provision of proven, reliable machine benefiting from latest technological and design enhancements High efficiency within the power ranges and applications served Operational confidence from beginning and beyond Assurance of continual service Maximises operational life 30MW multi-stage turbine. steamturbines@weirgroup.com 14
Please contact us for further details: Weir Engineering Services Pegasus House Bramah Avenue East Kilbride G75 0RD, UK Tel: +44 (0)141 308 2800 Email: servicesinfo@weirgroup.com Web: www.weirpowerindustrial.com Excellent Engineering Solutions Copyright 2013 Weir Engineering Services Ltd. All rights reserved. HOPKINSONS and AUTOTORK are trademarks and/or registered trademarks of Weir Valves & Controls UK Ltd; ALLEN STEAM TURBINES is a trademark of Weir Engineering Services Ltd; ROTO-JET is a trademark and/or registered trademark of Envirotech Pumpsystems, Inc; WEIR is a trademark and/or registered trademark of Weir Engineering Services Ltd. 6807/04/13