11. Safety Related Gear Drives
High Pressure
Coolant Injection
Charging Pump
Cooling Tower
Traveling Screen
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
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
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. Largest East Coast Consolidated (G.E.) PSV Commercial
Stocking Distributor – BOP Only
Stamps: “VR”, “NR-VR”, “V”, & “UV”
57. Limitorque Blue Ribbon Facility
Factory Authorized Service Center
Largest East Coast Limitorque Master Distributor
Expert BOP Sales, Service, and Field Support
58. Thermal
Spray 101
• What is Thermal Spray
• What is it Used For
• Typical Industrial
Applications
• Coating Deposition
Methods
• Process & Coating
Characteristics
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. 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. 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. 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. 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. 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. 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. Hydraulic Ram Refurbishment
• Thermal Spray Repair – Electric Arc
Spray w/ 400 series Stainless Steel
• Finish Grinding
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.
70. 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.
71. 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.
72. 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
73. 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
74. 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.
75. 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)
76. 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
77. 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.
78. 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.
79. 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
80. 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
81. 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
82. 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.
83. 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.
84. 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.
Notes de l'éditeur
HEADQUARTERED IN ASTON PENNSYLVANIA , CHALMERS & KUBECK IS THE LARGEST INDEPENDENTLY OWNED AND OPERATED INDUSTRIAL SERVICE PROVIDER ON THE EAST COAST. WE’RE ON THE APPROVED VENDORS LIST TO PERFORM SAFETY RELATED WORK FOR 4 DIFFERENT NUCLEAR COMPANIES AND ARE ANTICIPATING A NUPIC AUDIT IN 2016.
(CALLAWAY, DUKE, SOUTHERN AND PG&E – WE HAVE ALSO BEEN AUDITED BY SOUTH TEXAS AND THEY WILL ADD US TO THEIR ASL WHEN THEY REQUIRE OUR SERVICES)
(READ SLIDE) C&K HAS 7 INTEGRATED DEPATMENTS INCLUDING CNC MANUFACTURING, GEAR SERVICES, ROTATING EQUIMPMENT & FIELD MACHINING, WELDING & FABRICATION, ENGINEERED PUMPS, THERMAL SPRAY & GRINDING, AND VALVE SALES & SERVICE.
OUR GEAR DEPARTMENT HAS BEEN A MEMBER OF THE AMERICAN GEAR MANUFACTURER'S ASSOCIATION SINCE 1989 AND ACTIVELY PARTICIPATES IN TWO OF THEIR TECHNICAL COMMITTEES. LAST YEAR, OUR GEAR DEPARTMENT MANAGER WAS ELECTED TO THE AGMA BOARD OF DIRECTORS, WHICH IS A DISTINCTION HISTORICALLY RESERVED FOR OEMS.
WE CAN REVERESE ENGINEER REPLACEMENT GEAR SETS ,AND USING OUR HOFLER 2000, CAN MANUFACTURE PRECISION GROUND SPUR, HELICAL, AND DOUBLE HELICAL GEARS UP TO 2M IN DIAMETER. WE HAVE A CALIBRATED GEAR CHECKER TO PERFORM INDEPENDENT VERIFICATIONS.
WITH A DIFFERENT HEAD ATTACHMENT, OUR HOFLER CAN PERFORM ID FORM GRINDING ALONG WITH ONBOARD CHECKING OF GEAR TOOTH GEOMETRY.
WE ARE A SIEMENS FLENDER AUTHORIZED REPAIR CENTER – AS YOU’RE TOURING OUR SHOP, YOU MAY GET AN OPPORTUNITY TO SEE SOME SIMILAR, BUT MUCH MORE MASSIVE PLANETARY GEAR DRIVES UTILIZED BY THE CEMENT INDUSTRY.
WE HAVE SAFETY RELATED NUCLEAR GEAR WORK IN HOUSE FROM 4 DIFFERENT UTILITIES
PICTURED IS A SAFETY RELATED WESTINGHOUSE / NUTTALL CHARGE PUMP DRIVE FROM PG&E DIABLO CANYON. THIS UNIT IS IN FOR A COMPLETE OVERHUAL INCLUDING MANUFACTURING OF A NEW GEAR SET THAT WILL FAR EXCEED THE QUALITY OF THE ORIGINAL HOBBED GEAR SET.
(Ameren, Callaway- Marley Cooling Tower Drive overhaul, Spin Test with Callaway NOS present
Southern Company, Vogtle - Marley Cooling Tower Drive overhaul, ditto of Callaway Drive
Pacific Gas & Electric, Diablo Canyon - Westinghouse / Nuttall Charge Pump Drive- complete overhaul including Reverse Engineering, manufacturing of a new gear set, up - graded metallurgy, spin tested with PGE NOS present.
DUKE Energy- Catawba - New Gear Set, Westinghouse / Nuttall Charge Pump, Reversed Engineered, manufactured , up-graded metallurgy. Gear Set to be installed by C&K Technicians on -site during a future Catawba Sta. outage)
(WE CURRENTLY DO NOT PERFORM COMMERCIAL GRADE DEDICATION, BUT ARE WORKING WITH THIRD PARTY VENDORS TO PERFORM THIS FUNCTION)
COMPLETE TURN KEY OVERHAULS
BASKETS, LINKAGES, BUSHINGS, HEAD SHAFT, SPROCKETS, TENSIONERS, NEW WELDED STAINLESS PIPING, & ASSOCIATED HYDRO TESTING
WE CAN PERFORM TURN KEY REBUIDS AT YOUR SITE, LASER ALIGNMENTS, BORE SCOPE INSPECTIONS FOR PREDICTIVE MAINTENANCE, AND VIBRATION ANALYSIS TO DIAGNOSE EQUIPEMENT ISSUES.
OUR COMPREHENSIVE FIELD MACHINING SERVICES INCLUDE (READ SLIDE).
PICTURED IS A REPAIR TO A WESTINGHOUSE SWIRLER BURNER FOR A GAS TURBINE UNIT – WE PERFORM EXTENSIVE OUTAGE SER
OUR MACHINING AND MAINTENANCE DEPARTMENT PROVIDES EMERGENCY REPAIR SERVICES AND PERFORMS COMPLETE OVERHAULS OF PUMPS, TURBINES, HEAT EXCHANCGERS, BLOWERS, FANS, COMPRESSORS, AND CENTRIFUGES TO NAME A FEW.
C&K MANUFATURES NUMEROUS QUALITY REPLACMENT PARTS FOR MAJOR POWER INDUSTRY OEMs INCLUDING SIEMENS, GE/ALSTOM, MITSIBUSHI, AND WESTINGHOUSE NUCLEAR. WE ARE ALSO A SUPPLIER TO AIR PRODUCTS, GENERAL DYNAMICS / ELECTRIC BOAT (NUCLEAR SUBMARINES), AND METSO MINERALS.
FABRICATION & MACHINE, NDE, BALANCE, OVERSPEED TESTING
OUR CNC MANUFACTURING DEPARTMENT OFFERS VARIOUS REVERSE ENGINEERING, LAYOUT, LEVELING, AND INSPECTION SERVICES USING OUR FARO EDGE C-M-M ARM WITH LASER SCANNER AND OUR TWO FARO LASER TRACKERS.
OBSOLETE NON-SUPPORTED PART? - NO PROBLEM
THESE TECHNOLOGIES ARE A SIGNIFICANT TIME SAVER WHEN COMPARED TO TRADITIONAL MEASURING TECHNIQUES. IN ADDTION TO OUR LASER TRACKER SHOP SERVICES, WE ALSO OFFER IN-FIELD / ON SITE SERVICES COMPLETE WITH A REPORT PACKAGE.
(Faro Edge Accuracy 0.0009” @ 1.8M & 0.0011” @ 2.7M)
(Faro ION Accuracy 0.0004” In-Line @ 8m, 0.0009” Horizontal Scale Bar @ 2m, 0.00019 Horizontal Scale Bar @ 10m)
PICTURED IS AN AIR PRODCUTS AIR BEARING. TURNING, MILLING, ANGLE HOLES & POCKETS. BUILT-IN QUALITY / RIGHT FIRST TIME IS A MUST WHEN YOU’RE DEALING WITH SUCH A LARGE AND EXPENSIVE CASTING.
THIS PICTURE ALSO SPEAKS FOR ITSELF AS A TESTAMENT TO OUR MACHINING CAPABILITIES.
OUR WELDING ACCREDIATIONS INCLUDE:
NUCLEAR REPAIR, REPAIR, AND ASME PRESSURE VESSEL, POWER PIPING, PROCESS PIPING, AND PRESSURE PIPING. WE HAVE OVER 130 QUALIFIED WELDING PROCEDURES.
PICTURED IS A REVERSE ENGINEERED PUMP TRANSITION COLUMN FABRICATED AND MACHINED IN HOUSE TO SUPPORT OUR ENGINEERED PUMP DEPARTMENT.
THIS STELLITE HARDFACING AND MACHINING WAS EMERGENT WORK PERFORMED TO SUPPORT A LOCAL FOSSIL PLANT OUTAGE.
THIS IS AN EXAMPLE OF A LARGE PRESSURE VESSEL FABRICATED UNDER OUR “U” STAMP.
PEACH BOTTOM STEAM DRYER LIFTING FIXTURE FABRICATED FOR A MAJOR OEM - JOHN WILL TAKE A MOMENT TO SPEAK BRIEFLY ABOUT THIS PROJECT
DESIGNED BY WESTINGHOUSE NUCLEAR
4 PNEUMATICALLY ADJUSTABLE LIFTING ARMS
C&K PROJECT – WELDING, FABRICATION, AND TESTING
EXELON PEACH BOTTOM NUCLEAR WASTE STORAGE CASK
OUR ENGINEERED PUMP DEPARTMENT MANAGEMENT TEAM IS EX-FLOWSERVE AND INGRESOLL DRESSER FACTORY TRAINED. WE PERFORM COMPLETE OVERHAULS TO OEM SPECIFICATIONS AND CAN PROVIDE SERVICES INCLUDING FAILURE ROOT CAUSE ANALYSIS, MECHANICAL ANLYSIS, AND HYDAULIC ANALYSIS. WE SPECIAILZE IN UPGRADES TO INCREASE PUMP PERFORMANCE, RELIABILITY, AND DURABILITY.
PICTURED IS AN OVERHAULED HIGH SPEED BARREL STYLE PUMP THAT HAD RUNNING CLEARANCES, STRAIGHTNESS, AND FITS RESTORED TO OEM SPECIFICATIONS.
MACHINING EXPERTISE – QUALITY RESULTS
RESTORE INSTEAD OF REPLACE. SAVE BOTH MONEY AND ALMOST MORE IMPORTANTLY, AVOID LENGTHY FOUNDRY LEADT TIMES!
JOHN, I BELIEVE YOU HAVE A STORY ABOUT A NUCLEAR OEM PUMP CASE (METAL STITCH)
YOU’LL LEARN MORE ABOUT THERMAL SPRAY REPAIRS IN THE NEXT SEGMENT OF THIS LUNCH AND LEARN, BUT THIS IS AGREAT EXAMPLE OF A THERMAL REPAIR OF A PUMP CASE. AS YOU CAN SEE IN THE PHOTO, THE BEARING FITS, STUFFING BOX FITS, AND CASE RING FITS WERE RESTORED. THE SPLIT LINES WERE MACHINED AND THE CASE WAS LINE BORED.
PICTURED IS A BRONZE CIRCULATING WATER PUMP THAT WAS REFURBISHED USING ALUMINUM BRONZE THERMAL SPRAY.
IT HAD SEVERE VANE CAVITATION DAMAGE AND REQUIRED VANE UNDERFILIING TO ENHANCE PUMP CAPACITY. THE IMPELLER WAS PREVIOUSLY REPAIRED USING AN EPOXY COATING THAT WAS NOT AN EFFECTIVE LONG TERM SOLUTION.
(10T - 6,740 psi)
PICTURED IS A PUMP DISCHARGE HEAD THAT WE REVERSE ENGINEERED, FABRICATED, AND MACHINED AS PART OF A COMPLETE PUMP OVERHAUL. OUR MULTI-SHIFT OPERATION AND EXTENSIVE IN-HOUSE CAPABILITIES ALLOW US TO MAINTAIN TIGHT CUSTOMER DRIVEN SCHEDULES.
THIS CIRCULATING PUMP WAS OVERHAULED FOR EXELON IN A VERY TIGHT CUSTOMER DRIVEN TIME FRAME. OUR LARGE MACHINING CAPACITY PLAYED A CRITICAL ROLE IN OUR ABILITY TO MEET CUSTOMER DELIVERY REQUIREMENTS.
THIS IS AN EXCELLENT EXAMPLE OF WHERE EPOXY COATING HAS ITS PLACE IN PUMP REFURBISHMENTS. WE’VE OVERHAULED AND UPGRADED A NUMBER OF THESE CIRC WATER PUMPS FOR PS&G SALEM AND WILL HIGHLIGHT THIS LATER AS A COST AVOIDANCE CASE STUDY. JOHN, DO YOU WANT TO SAY A FEW WORDS ABOUT THE WET END UPGRADE?
PICTURED IS AN EXAMPLE OF AN OVERHAULED SAFETY RELATED SERVICE WATER PUMP OVERHAULED AT OUR FACILITY.
(WE WORKED UNDER PS&G NUCLEAR OVERSIGHT)
PICTURED IS AN OVERHAULED 9 STAGE 29APKD INGERSOLL RAND THAT WAS COMPLETELY OVERHAULED TO OEM SPECIFICATIONS.
LIKE ANY DEPARTMENT AT CHALMERS & KUBECK, THE ENGINEERED PUMP DEPARTMENT OFFERS COMPLETE TURN KEY FIELD SERVICE SUPPORT INCLUDING PULL-OUT, INSTALLATION, ALIGNMENT, START-UP, AND TECHNICAL TRAINING / SUPERVISION.
OUR 27,000 SQUARE FOOT VALVE PLANT, ALSO LOCATED IN ASTON PA, OFFERS UNPARALLELED OUTAGE SUPPORT SERVICES WITH ITS TWO SHIFT OPERATION AND 5 RELIEF VALVE TEST STATIONS. OUR SKILLED VALVE PLANT PERSONEL ALSO PROVIDE FIELD SUPPORT SERVICES FOR RELIEF VALVES, LINE VALVES, AND ACTUATORS.
AS THE LARGEST GE GREEN TAG CENTER ON THE EAST COAST FOR CONSOLIDATED RELIEF VALVES, WE WORK WITH OUR CUSTOMERS TO UNDERSTAND THEIR INSTALLED VALVE BASE AND STOCK >$5M IN NEW VALVE PARTS ENABLING US TO RESPOND QUICKLY TO THEIR NEEDS.
ASME Section I (“V” Stamp – Boiler Safety Valves) & III (“UV” Stamp – Pressure Vessel Safety Valves)
National Board “VR” Stamp Section I, III (Class 2 & 3), VIII Division I – Pressure Relief Valve Repair
HYDROSTATIC TESTING OF LINE VALVES UP TO 20,000 PSI
(Flange Connections – up to 48” various ratings; Butt Weld Connections – up to 12” at 1,500 psi)
WE ARE THE LARGEST LIMITORQUE DISTRIBUTOR ON THE EAST COAST
EXPERT SALES, SERVICE, AND FIELD SUPPORT FOR BALANCE OF PLANT APPLICATIONS
WE’LL TAKE A QUICK 10 MINUTE BREAK HERE. WHEN WE COME BACK, WE’LL TAKE A FEW MINUTES TO ANSWER (ADDITIONAL) QUESTIONS BEFORE WE LEARN ABOUT THERMAL SPRAY 101.
(READ SLIDE)
PICTURED ARE TWO NEW PUMP SHAFT SLEEVES THAT HAVE BEEN UPGRADED WITH A HIGH PERFORMANCE TUNGSTEN CARBIDE COATING. THIS COATING WAS APPLIED WITH OUR PRAXAIR JP-8000 HIGH PRESSURE HIGH VELOCITY OXYGEN FUEL SYSTEM (HP HVOF), DIAMOND GROUND AND SUPER FINISHED; IT HAS A SURFACE HARDNESS OF APPROXIMATELY ~ 64 ON THE ROCKWELL C SCALE.
What is Thermal Spray?
It’s a group of processes where a surfacing material (in the form of a wire or powder) is heated to a molten or semi-molten state and then accelerated onto the base material by compressed gases. As the melted or softened particles strike the base material, they flatten and adhere to the irregularities of the prepared surface. As the sprayed particles cool, they build up into a dense well bonded coating.
THERMAL SPRAY – WHAT IS IT USED FOR?
THERMAL SPRAY IS A COST EFFECTIVE MEANS FOR RECLAMATION / SURFACE RESTORATION OF WORN OR MISS-MACHINED PARTS WITHOUT THE DISTORTION OF WELDING.
AN ALMOST LIMITLESS NUMBER OF THERMAL SPRAY COATINGS ARE AVAILABLE TO ENHANCE PERFORMANCE / SERVICE LIFE OF PARTS SUBJECT TO FRETTING, WEAR, GAULLING, EROSION, CORROSION, OXIDATION, AND/OR HIGH TEMPERATURES.
THERMAL SPRAY COATINGS HAVE BEEN USED THROUGHOUT INDUSTRY TO BOTH RESTORE COMPONENTS THAT HAVE SERVICE INDUCED WEAR OR DAMAGE AND TO UPGRADE THE SURFACE PROPERTIES OF COMPONENTS AND STRUCTURES FOR EXTENDED FUNCTIONAL SERVICE LIFE.
(400 S.S. – 13% Chrome 4,730 PSI, 40-43 Rc))
THERE ARE SEVERAL DIFFERENT THERMAL SPRAY DEPOSITION METHODS.
THEY DIFFER IN THE SOURCE MATERIAL – WIRE OR POWDER. AND THE ENERGY APPLIED TO THE SOURCE MATERIAL - A COMBINATION OF THERMAL (HEAT) AND KINETIC (VELOCITY).
EACH DEPOSITION METHOD HAS ITS ADVANTAGES AND SOME ARE OPTIMIZED FOR A SPECIFIC TYPE OF COATING.
(READ SLIDE)
ELECTRIC ARC WIRE SPRAY ALSO REFERRED TO AS “TWIN ARC” IS
A THERMAL SPRAY PROCESS WHERE TWO CONSUMABLE WIRE ELECTRODES ADVANCE TO MEET AT A POINT IN AN ATOMIZING GAS STREAM.
AN ELECTRIC POTENTIAL APPLIED ACROSS THE ELECTRODES INITIATES AN ARC THAT MELTS THE TIPS OF THE ELECTRODES AND A COMPRESSED AIR STREAM PROPELS THE MOLTEN ELECTRODE MATERIAL(S) ONTO THE PREPARED SUBSTRATE.
(READ SLIDE)
(((Read Slide)))
The HVOF or High Velocity Oxygen Fuel thermal spray deposition method uses a high pressure combustion flame to heat and propel the powder particles – it has the highest kinetic energy of the thermal spray processes with particle velocities exceeding Mach 2. This high velocity results in very dense coatings with low porosity and extremely high bond strengths.
HCAT, or the Hard Chrome Alternatives Team, composed of US and Canadian DOD, aerospace companies, and military overhaul depots has recommended HVOF as the method of choice for Hard Chrome replacement. In fact, the Tungsten Carbide Coatings tested yielded a functional service life 3x or more compared to Hard Chrome! All landing gear cylinders on new aircraft designs are now specified with HVOF including the Airbus A380, Boeing 787 Dreamliner, the F-35 Joint Strike Fighter (top photo), and the Semi-Autonomous experimental X-45 (bottom photo).
(((The US Navy uses coatings of WC-Co on steering rams, CrC-NiCr on missile boat propulsion shafts and gas turbine shafts, Ni-Cr-B on destroyer stabilizer hydraulic rams, and for naval steering pistons Ni-Cr-B on the journals and Ni-B-Si on the bearing areas.)))
(READ SLIDE)
WHILE THE TEMPERATURE IN THE PLASMA PLUME IS EXTREMELY HOT, THE TEMPERATURE OF THE PIECE OF EQUIPMENT BEING COATED IS CONTROLED TO BE BELOW 375F. THE PART DOES NOT DISTORT.
THERMAL SPRAY COATING CHARACTERISTICS & LIMITATIONS
THE APPLICATION OF THERMAL SPRAY IS A LINE OF SITE PROCESS SIMILAR TO SPRAY PAINTING AND THE STAND OFF DISTANCE IS CRITICAL. INTERNAL DIAMETERS CAN BE THERMAL SPRAYED USING A SPECIAL I.D. GUN OR ATTACHMENT. ((RULE OF THUMB IF NOT PERPENDICULAR IS 1” DEPTH PER 1” DIAMETER))
UNLIKE A FUSION WELD, THE BONDING METHOD IS PRIMARILY MECHANICAL. SURFACE PREPARATION TYPICALLY INCLUDES CLEANING, DE-GREASING, UNDERCUT, AND GRIT BLAST OR HEAT AND THREAD. CONTROL OXIDATION OF THE BASE METAL – LIMIT TIME BETWEEN SURFACE PREP AND SPRAYING.
When it comes to pumps, one of the most common items thermal sprayed are wear sleeves for rotating elements. These sleeves can be dimensionally restored using thermal spray and then upgraded with a protective coating to increase durability and reliability. The protective coatings can be applied to new sleeves (requires undercut) or to sleeves that have been dimensionally restored.
The large sleeve pictured on the left was manufactured new out of Monel and then upgraded with an Atmospheric Plasma Spray Chrome Oxide coating for wear and corrosion resistance (69-75 Rc) . The smaller sleeve was a Nitronic-50 material that had service induced wear – it was undercut, bond coated with Ni-5Al, dimensionally restored using 400 S.S. and then upgraded with a HVOF Tungsten Carbide 17% Cobalt coating (64 Rc) to increase wear resistance.
THIS IS A TMI SUCCESS STORY (READ PROBLEM)
THIS 2-STAGE HEATER DRAIN PUMP WAS IDENTIFIED BY A KENNETT SQUARE SENIOR VP (RON DeGREGORIO) AS ONE OF THE MOST PROBLEMATIC PUMPS AT TMI. IN 2009, C&K WORKED WITH MATT KRAUSE TO DEVELOP A SOLUTION TO THIS CHRONIC SEAL FAILURE ISSUE.
(READ SOLUTION) C&K MANUFACTURED THE CENTER SLEEVE, GRAPHALLOY CENTER BUSHING, 4 CASE WEAR RINGS, 4 IMPELLER WEAR RINGS, AND 2 STUFFING BOX SLEEVES.
THE PUMP WASN’T OPERATED FOR A. PERIOD OF TIME BETWEEN 2005-2009 DUE TO VIBRATION ISSUES
11 seal replacements / 15 years * (7K seals +15K labor) = 16.1K / Year * 6 years (since 2009) = $97,000
C&K overhauled the element for $57K which included
CAPTURE RUNAWAY REPLACEMENT COSTS!
IN 2009, SALEM NUCLEAR GENERATING STATION ACHIEVED OVER $4MM IN COST AVOIDANCE DUE TO THERMAL SPRAY SURFACE RESTORATION AND UPGRADES PERFORMED BY C&K. IN ADDITION TO REFURBISHING WORN PARTS, C&K IS LISTED IN THE PSE&G DATABASE AS THE PREFRERRED VENDOR TO MANUFACTURE NEW UPGRADED REPLACMENT PARTS THAT HAVE THERMAL SPRAY COATINGS.
Ni-5AL to restore dimensions
PICTURED ON THE LEFT IS A GROOVE IN THE STRAINER BODY FROM RIVER SILT ERROSION AT THE O-RING
Cr2O3-SiO2-TiO2
Chrome Oxide w/ 5% Silicon Oxide & 3% Titanium Oxide
75B – 9,750 psi Bond Strength
THE OEM WOULD NOT REPAIR THIS SERVICE WATER STRAINER SHAFT. C&K REPAIRED AND UPGRADED THE CERAMIC COATING FOR $63K IN COST AVOIDANCE.
WHEN THIS SHAFT WAS REMOVED FROM SERVICE 4 AND A HALF YEAR LATER FOR INSPECTION, THERE WAS NO WEAR ON THE COATING. IT WAS CLEANED, POLISHED, AND RETURNED TO SERVICE.
NEW SERVICE WATER CONE IS $300K WITH A 55 LEAD TIEM FROM THE OEM. C&K RESTORED THIS COMPONENT IN ONLY 3 WEEKS WITH A COST AVOIDANCE OF APPROXIMATELY $275K
SP KINNY MODEL A 20”
C&K has also field repaired an even larger strainer – for service water - where the cost to remove the body for repair and/or replacement was cost prohibitive due to accessibility and rigging challenges. In this instance, the strainer body was cast bronze and, due to the alloy composition, it wasn’t weldable.
The solution was to field repair the strainer body at the customers’ site using Aluminum Bronze. Thermal Spray coupled with field machining using a C&K machine tool designed and and built for this application. Other large strainers with Monel Inserts have been similarly repaired using Monel thermal spray.
For this success story, the strainer body was repaired at a fraction of the rigging cost without even considering the additional cost of an OEM repair and/or replacement. 3 years following the repair, the strainer body was inspected and there was no indication of wear, a testament that sprayed coatings wear better than the original as cast material. This repair netted $528K in cost avoidance without the long lead time associated with OEM replacement parts.
(Strainer Body > $300,000 to purchase new, Removal / re- installation ~$350,000
(Cr2O3-SiO2-TiO2)
Running clearances reduced from .025” to .015”
Vibration reduced from >46 mils to <10 mils
LETS PUT SOME NUBMERS TO THAT: PSE&G HAS 13 CIRCULATING PUMPS AND WAS DOING FOUR REBUILDS PER YEAR AND NOW ONLY NEEDS TO DO TWO REBUILDS PER YEAR FOR A SAVINGS $600K – $1M/YEAR NOT INCLUDING THE ASSOCIATED REMOVAL, TRANSPORATION, AND INSTALLATION COSTS.
WE HAVE ALSO THERMAL SPRAYED CASE REGISTER FITS WHEN NOT WELDABLE.
One of the most common pump components thermal sprayed are wear sleeves for rotating elements. Worn sleeves can be dimensionally restored using thermal spray and then upgraded with a protective coating to increase durability and reliability. High performance coatings can also be applied to new sleeves (requires undercut).
The large sleeve pictured on the left was manufactured new out of Monel and then upgraded with an Atmospheric Plasma Spray Chrome Oxide coating for wear and corrosion resistance (69-75 Rc) . The smaller sleeve was a Nitronic-50 material that had service induced wear – it was undercut, bond coated, dimensionally restored using 400 S.S. and then upgraded with a HVOF Tungsten Carbide coating (64 Rc) to increase wear resistance.
SO, WHAT DID ALL THIS COST?
TO REPAIR THE ABOVE COMPONENTS, INCLUDING UPGRADED COATINGS, AND COMPOSITE BEARING MATERIAL NETTED A $250K COST AVOIDANCE COMPARED TO PURCHASING NEW “STANDARD” PARTS FROM THE OEM. THIS COST SAVINGS DOES NOT ACCOUNT FOR ANY OF THE INCREASED RELIABILTY AND DURABILTY AFFORDED BY THE UPGRADED COMPONENTS.
(OEM PARTS SHOWING SIGNIGICANT DEGREDATION 3-4 YEARS DURING A 6 YEAR
6 YEAR OVERHAUL FREQUENCY EACH PUMP
4.5 YEAR DATA POINT: CHROMIUM OXIDE AGAINST CUTLESS = NO WEAR OF COATED SHAFT
TYPICAL NITRONIC 50 SHAFT / SLEEVES WOULD BE OUTSIDE ASSEMBLY SPEC AT THAT POINT AND REQUIRE REPLACMENT
EACH SECTION OF 3 PIECE SHAFT 60-70K. RESTORATION AND UPGRADE ~25%
INTERMEDIATE SERVICE INTERVAL FOR STUFFING BOX SLEEVE - ALWAYS NEEDED REPLACMENT AFTER 3 YEARS AND CHROMIUM OXIDE COATED SLEEVES HAVE BEEN IN-SERVICE TWICE THAT LONG. 18-19K PER SLEEVE (NEW).
(WE HAVE DATA ON SAME PUMP CHROME OXIDE AGAINST CUTLESS RUBBER NO WEAR OF THE CHROMIUM OXIDE COATING.
GOAL 6 YEAR PM TO 9 OR 12 YEARS)
.060-.070
UNPREDICATBLE START-UP ISSUE
Decreased durability and reliability. The pump seizures would take a crew of 5 people 7-10 days to repair.
During the repair, the plant would be at reduced capacity resulting in significant revenue loss (>$500,000 / DAY)
10 HE UNITS WERE SENT IN ON A RUSH BASIS DURING PSEG SPRING OUTAGE 14' DUE TO MIC DAMAGE TO THE TUBE SHEET FACES. THE 316 ST BASE METAL WAS NOT HOLDING UP IN SERVICE AND THEY WANTED TO UP GRADE THE COMPONENTS WITHOUT THE EXPENSE OF REPLACEMENT.
WE THERMAL SPRAYED THE ENTIRE "WETTED AREAS" WITH HASTELLOY C, WHICH TOTALLY ENCAPSULATED THE ORIGINAL BASE MATERIAL.
THEY RETURNED THEM TO SERVICE IN RECORD TIME AND AT FRACTION OF THE NEW REPLACEMENT COST.
