It is not always possible to carry out high-quality repairs of critical components and elements of power plant equipment in the conditions of existing production on the customer’s premises. Taking this fact into account, the plant has developed and has been using for many years the technology of transporting such units to the production base of the plant, where diagnostics of the technical condition and subsequent repairs are carried out in industrial-factory conditions on a turn-key basis, using, if necessary, special stands, special equipment and large-sized metal-cutting machines. All equipment on the balance sheet of the plant allows for high-precision processing of repaired units and its final adjustment in the factory, including control assemblies of turbine cylinders. After the components are repaired, they are bench adjusted, tested and delivered to the customer.
The production capabilities of the plant provide, within the production base, complete disassembly and assembly of all parts of turbine units, including stator and rotor parts of turbines.
QTMP LLP has a wide range of metal-cutting, bench and special equipment using modern cutting tools.
The technical capacity of the plant allows the following basic technological work to be carried out:
Turning works
- Largest processed diameters:
- above the bed - 2300 mm;
- above the caliper - 1950 mm.
- The longest length of the product is 7500 mm.
- The largest weight of the processed product is 25 tons.
- The roughness of the processed surfaces is up to 1.25 microns.
Milling, coordinate milling work
- The largest dimensions of the working surface of the table are 1400 x 2240 mm.
- The highest processing height is 920 mm.
- The largest weight of the processed product is 2.5 tons.
Horizontal boring work
- The largest dimensions of the working surface of the table are 1120 x 1250 mm.
- Largest diameter of boring hole:
- spindle 320 mm;
- caliper 600 mm.
- The largest weight of the processed product is 3 tons.
Carousel works
- The largest processed diameter is 3150 mm.
- The maximum height of the workpiece is 16000 mm.
- The largest weight of the processed product is 9 tons.
Work on dynamic balancing of rotors and shafts
- The largest diameter of the balanced product is 3200 mm.
- The maximum length of the balanced product is 7500 mm.
- The largest weight of the balanced product is 40 tons.
- Operating speed of the stand:
- cardan drive - 70...905 rpm;
- belt drive - 100...3800 rpm.
Welding work
The plant performs a wide range of welding and surfacing works, using argon-arc welding with a non-consumable electrode, manual electric arc, semi-automatic in shielding gases or with a special self-shielding wire, gas welding.
Welding and surfacing works are used to restore worn surfaces of parts, breakage and eliminate cracks in parts and products.
Main types of welding work:
- Welding of carbon and low-alloy structural steels;
- Welding of low-alloy heat-resistant steels with subsequent heat treatment;
- Repair of cast parts made of low-alloy heat-resistant and heat-resistant steels;
- Preliminary and concomitant heating of the welding zone (product) with subsequent heat treatment;
- Welding of stainless steels;
- Cast iron welding;
- Welding and surfacing of non-ferrous metals;
- Surfacing and refilling of sliding bearings with Babbitt B16, B83.
Heat treatment
Today, the plant has the opportunity to offer you the following list of services for heat treatment of metals and alloys, both in blanks and in finished parts:
- Annealing;
- Normalization;
- Hardening;
- Cementation.
The thermal section has furnaces with maximum working space dimensions: 600 mm x 800 mm x 1500 mm and 800 mm x h 1000 mm.
Plasma hardening
Plasma hardening is a type of surface hardening of steel and cast iron, which is a high-speed local heating of parts to high temperatures and rapid cooling, which is achieved by heat removal into the body of the part from the surface.
The hardened layer is 0.5...1.5 mm, which ensures good performance of gear and spline joints, crane rails and wheels, lining plates, etc. The hardened surface has no scale and is not damaged by melting, which allows many parts to be including gear and spline ones, send them into operation without additional machining or limit themselves to cleaning with a flap wheel. Hardening is carried out without accompanying cooling with water, which allows it to be carried out not only in thermal shops, but in a variety of places: at installation and repair sites, in the open air, at the place where parts are used.
Characteristics of the steel hardening layer:
- Hardness - HRC up to 65 (depending on steel);
- Depth - 0.5…1.5 mm;
- The minimum thickness of the product is 5mm.
Stand equipment and fixtures:
To carry out a full range of work related to the industrial-factory repair of the main and auxiliary equipment of power plants, the plant is equipped with a line of stands and complexes, special equipment that allows for turnkey repair of turbine rotors and rotating machines, including their complete disassembly and reassembly, defect detection, re-blading , technical condition check, setup and vibration adjustment.
The stands available at the plant’s production base allow for special machining of complex parts in hard-to-reach places, restoration of damaged rotor units and parts of turbine flow parts, as well as adjustment of steam turbine units and systems, including safety circuit breakers, units of automatic turbine control systems and steam distribution systems, individual components and systems of automated process control systems of power plants;
Along with the above technological operations, the plant also performs grinding, slotting, gear cutting, forging, and preparation work.
QTMP is equipped with a testing and adjustment stand for turbine safety circuit breakers, on which tests of both new and repaired safety circuit breakers are carried out. The use of a test bench allows for better tuning of such an important turbine unit as a safety circuit breaker and can significantly reduce the time for commissioning work at the station when putting turbine units into operation after repair or installation.
We can offer the development of technical documentation.
Consistently high quality of products is ensured not only thanks to the technical equipment of the enterprise, but also to strict adherence to quality standards at all stages of production.
The plant has a design and technology department, a technical control department and a metrological service, a metals and alloys control laboratory, a production dispatch department, a production preparation and planning service, the main task of which is to prevent the enterprise from releasing products that do not meet the requirements of standards and technical specifications, design - design and technological documentation, terms of delivery and contracts, or incomplete products, as well as strengthening production discipline and increasing the responsibility of all levels of production for the quality of products.
Focus on improving the quality of services and products provided is the most important priority of the policy of QTMP LLP. The plant systematically works to improve production and technological processes, improve personnel qualifications, improve working conditions, increases the technical re-equipment of its production, actively studies, generalizes and uses the experience of leading manufacturers of turbine equipment.
