brush sem site facilities brochure
TRANSCRIPT
BRUSH SEM
Site Facilities
Brochure
BRUSH SEM Site Facilities Brochure
ABOUT US
BRUSH SEM s.ro.
Tř. Edvarda Beneše 39/564,
301 00, Plzeň, Czech Republic
Phone: +420 378 210 555
E-mail: [email protected]
Web: www.brush.eu
www.brush-sem.cz
Plzeň:
traditional industry city
4th largest city in Czech Republic
University & regional centre
History
1859 mechanical works by Earl Waldstein
1869 Emil Škoda plant
1922 Electrical engineering plant Doudlevce
1924 1st air cooled turbogenerator (17 MVA)
1966 1st hydrogen & water cooled turbogenerator
1994 turbogenerator 1,111 MVA
2001 acquired by FKI Plc & BRUSH
2008 acquired by Melrose Plc
Factory:
total area 95,000 m2, built-up area 63,700 m2
the manufacturing area is split into two workshops:
o six bay workshop 200 x 200m with crane capacities up to 210 tonnes
o heavy workshop 36 x 78m with crane capacity up to 400 tonnes
o road transport up to 200 tonnes, rail transport up to 400 tonnes
Manufacturing facilities comprise the following:
o Fabrication, Pressing, Machining, Coil & Copper Shop, Winding, Assembly, Testing
Certificates:
BRUSH SEM Site Facilities Brochure
FABRICATION
General
Shop area: 3,350 m2
Overhead cranage: up to 400 tonnes
Heights of lift up: to 19 m
Cutting machine
Up to 10 mm thick and 2,000 mm length
Up to 3 mm thick and 3,000 mm length
Plate, bar and section cutting
All these materials are bought in cut to length
Forming
CNC Press-brake TRUMABEND 300 tonnes x 3,000 mm
Roll initial pinch bending rolls:
roller diameter 345 mm, length up to 3,000 mm
roller diameter 215 mm, length up to 2,000 mm
Straightening roll – 20 mm thick x 2,000 mm wide
Up-stroking 400 tonnes platen press (maximum width
3,000 mm)
Planning
Planer for edge profiling (plates up to 10,000 mm long)
Welding
Welding rectifier up to 600 amps, shielded arc welding
M21 up to 600A, Argon-arc welding up to 315 amps,
slotting with carbon electrode
MIG, MAG, TIG, stick electrode, gas welding
Used material:
W01 unalloyed, W02 alloyed steel – 0.2-250 mm
W11 stainless steel – 2-30 mm
Al, Cu – 3-30 mm
Heat treatment
Electric oven REALISTIK: 3,000 x 2,000 x 1,500 mm
maximum loading capacity 6 tonnes, max. temperature
1,000ºC
Shot blasting - blast room size:
9,000 long x 5,000 wide x 4,000 high
max. loading capacity 90 tonnes
iron blasting
Painting - room size:
10,000 long x 4,000 wide x 5,000 high
BRUSH SEM Site Facilities Brochure
PRESSING
General
Shop area: 440 m2
Overhead cranage: up to 5 tonnes
Shearing machine
up to 2.00 mm
Press line Rowe Machinery &
Manufacturing 3150 kN
table size 2,000 x 1,250 mm, lift 120 mm
Crank press 2000 kN
table size 1,505 x 1,025 mm, lift
200 mm
Crank press 5000 kN
table size 1,580 x 1,245 mm, lift
100 mm
Crank press 12500 kN
table size 1,600 x 1,850 mm, lift
150 mm
Eccentric press 1600 kN
table size 990 x 710 mm, lift 20-120 mm
De-burring machine
sheet thickness from 0.2-1.5 mm
width from 0.35-1.00 m
Painting machine
sheet thickness from 0.3-1.0 mm,
double-sided
width from 0.35-1.00 m
Hydraulic press MULLER 2000 kN
+ roll feeder Atkin
BRUSH SEM Site Facilities Brochure
COIL & COPPER SHOP
Diamond coils (for hydrogenerators & motors)
voltage 6.3; 11; max. 13.8 kV, insulation type F
max. length 2.7 m, max. length of straight part 1.5 m, max. weight 30 kg, max. cross
section 750 mm2, max conductor width 14 mm
Non-roebled coils (for turbo & hydrogenerators & motors)
voltage 11; 13.8; max. 15.0 kV, insulation type F
max. length 4.0 m, max. length of straight part 3.15 m, max. weight 30 kg, max. cross
section 900 mm2, max conductor width 15 mm
Roebled bars (for turbo & hydrogenerators & motors)
voltage 11; 13.8; 15.75; 20.0; 22.0; 24.0 kV,
insulation type F
max. length 11.25 m, max. length of straight part
7.6 m, max. weight 290 kg, max. cross section
2,700 mm2, max. conductor width 12 mm
Winding insulation technology resin-rich:
for voltage up to 15.75 kV Mica - PETP,
for voltage up to 24.00 kV Mica - Glass
Roebel machine Vincent Industrie VI-BC 10540 H
conductor width 4-15 mm
conductor thickness 1-4 mm
wire length 2-14 m
Roebel forming zone length 0.72-13.28 m
type of standard transposition 360°, 540° or 720°
other specific transpositions 300-900°
conductors per bar 80 (300 mm)
Presses: MicaMation (with overhang pressing), Rotary
Taping machine MicaMation MI 258-10000 range:
length X-axis 9,500 mm
width Y-axis 2,000 mm
height Z-axis 800 mm
rotation A-axis 360° (endless)
tilting B-axis ± 75°
swivel C-axis ± 85°
Press with electric heating for hydro generators
maximum working pressure 800 tons
upstroke 160 mm
oil pressure 16 MPa
pressing table 1,000 x 3,000 mm
Winding machines for rotor coils
maximum diameter - round and oval coils - 4,000 mm
BRUSH SEM Site Facilities Brochure
WINDING
Winding Shop provides the capability for complete stator & rotor winding including
manufacturing of insulation parts and final impregnation.
Insulation material machining
lathe
drilling machine
milling machine
planer
circular and band saw
We have 3 ovens, maximum capacity is:
drying kiln type P 1765
input 1,200 kW
max. temperature 170°C
width 6.0 m
high 6.5 m
length 14.0 m
loading capacity 350 tonnes
Utilized brazing technologies
torch brazing
resistance welding
HF soldering equipment (ELVA)
BRUSH SEM Site Facilities Brochure
MACHINING
Shop area
2 bays + 1 annex = 2x 4,375 + 1,650 = 10,400 m2
Overhead cranage
each bay 1x 50 t crane & 1x 100 t crane; annex 25 t crane
1 off Vertical Boring Machine (diameter 12.5 m)
table size up to 8 m, height up to 6.35 m, weight up to 120 t
2 off Vertical Boring Machines (diameter 5 m)
table size up to 4.75 m, height up to 3.5 m, weight up to 80 t
3 off Vertical Boring Machines (diameter 2.5 m)
table size up to 2.5 m, height up to 1.5 m, weight up to 14 t
1 off Horizontal boring machine HCW 3-200
table size up to 4 x 5 m, table stroke up to 8 m,
height up to 5 m, weight up to 95 t
2 off Horizontal boring machine WD 200
table size up to 2 x 2 m, table stroke up to 8 m,
height up to 4 m, weight up to 20 t
4 off Horizontal boring machine WD 160
table size up to 2,5 x 2 m, table stroke up to 7 m,
height up to 3 m, weight up to 20 t
1 off CNC Milling Machine
table size up to 4 x 1 m, weight up to 9 t
travels up to 4.0 m (x-axis), 1.0 m (y-axis), 1.4 m (z-axis)
1 off Slotting machine WPC 32 CNC
chuck diameter up to 0.9 m, length up to 10 m,
table size 2 x 5 x 1.1 m, weight up to 60 t
1 off Slotting machine HELLER
Length up to 9 m (X axis), Y axis up to 600 mm,
chuck diameter up to 550 mm, weight up to 35 t
1 off Slotting machine FP 20
size up to 1 x 4 x 1 m, weight up to 10 t
6 off Lathes
chuck diameter up to 3.2 m, length up to 17 m,
weight up to 100 t, 250 t (supported stand)
BRUSH SEM Site Facilities Brochure
ASSEMBLY
Shop area
2 bays = 2x 2,125 = 4,250 m2
Overhead cranage
1. bay
2x 100 t crane
+ auxiliary cranes
2. bay
1x 100 t & 1x 130 t crane
+ auxiliary cranes
Shop activities
assembly & testing & preparation for dispatching of air cooled turbogenerators
up to total weight 210 t
assembly & testing & dispatching of hydrogen or hydrogen & water cooled turbogenerators
up to stator weight 210 t
assembly of hydrogenerators
manufacturing of piping systems for turbogenerators & hydrogenerators
manufacturing of gas & oil systems for hydrogen or hydrogen & water cooled
turbogenerators
Shop equipment
lift platforms for work at a height, lifting range 6 m, 8 m & 9 m
hydraulic cylinders up to lifting capacity 100 t and lifting up to 50 mm
electric & pneumatic tools
torque wrenches & accurate equipment Hytorc with tightening torque up to 4,000 Nm
BRUSH SEM Site Facilities Brochure
TESTING
Small Balancing Tunnel
max. weight up to 34 tonnes
max. bearing inside diameter 400 mm
max. rotor diameter 2,550 mm
max. rotation speed 3,600 rpm
max. overspeed test 4,500 rpm
max. rotor length 9,000/11,000 mm
Large Balancing Tunnel
max. weight up to 80 tonnes
max. bearing inside diameter 560 mm
max. rotor diameter 3,800 mm
max. rotation speed 3,600 rpm
max. overspeed test 4,320 rpm
max. rotor length 11,500/13,500 mm
High-voltage test
maximum voltage 200 kV / 50 Hz by maximum load 0.11 μF
maximum voltage 100 kV / 50 Hz by maximum load 0.12 μF
maximum voltage 50 kV / 50 Hz by maximum load 0.51 μF