STORK & AES REPLACE CRACKED BLADES
STORK & AES WORK TOGETHER TO REPLACE CRACKED LP-0 BLADES
SHORTEST TURNAROUND PERIOD, HIGHEST QUALITY
In May 2017 Stork & AES Corporation, Mitsui and Co Ltd and Nebras power cooperated to achieve a solution for an unexpected challenge, namely the manufacturing of fourteen large LP-0 Blades for an OEM steam turbine at IPP Plant, located near Amman, Jordan. The blades needed to be replaced due to crack initiations in the curved side entry root. The cracks were found during a planned outage, although they did not expect to find any cracks during this inspection. When the cracks were discovered, a solution had to be found quickly in order to supply the required power for the summer season. Spare blades were not available and a long delivery time seemed to be the only option. These blades are normally made from closed die envelope forgings, which usually take more than six months to be made. Stork manufactured these replacement blades from a higher grade bar material to minimize downtime.
In the timespan of just over four weeks all necessary preparations were done and the blades were Engineered, Manufactured and Tested by Stork. This was economically the best option for the power plant in Jordan to continue operation as soon as possible while minimizing losses.
The AES Corporation
The AES Corporation (NYSE: AES) is a Fortune 200 global power company. We provide affordable, sustainable energy to 17 countries through our diverse portfolio of distribution businesses as well as thermal and renewable generation facilities. Our workforce of 19,000 people is committed to operational excellence and meeting the world’s changing power needs. Our 2016 revenues were $14 billion and we own and manage $36 billion in total assets. AES are dedicated to improving the lives of its customers by leveraging the energy solutions that encompass a broad range of technologies and fuel types, including coal, diesel, gas, oil, pet coke and renewables. AES people share a passion to help meet the world’s current and increasing energy needs, while providing communities and countries the opportunity for economic growth due to the availability of reliable, affordable electric power. To learn more, please visit www.aes.com. Follow AES on Twitter @TheAESCorp.
Mitsui & Co. Ltd.
Utilizing the global operating locations, network and information resources, Mitsui is multilaterally pursuing business that ranges from product sales, worldwide logistics and financing, through to the development of major international infrastructure and other projects in the following fields: Iron & Steel Products, Mineral & Metal Resources, Infrastructure Projects, Integrated Transportation Systems, Chemicals, Energy, Food, Food & Retail Management, Healthcare & Service, Consumer Business, IT & Communication Business, Corporate Development Business. http://www.mitsui.com/jp/en/index.html/
Nebras is a dynamic energy company headquartered in Doha, Qatar. Nebras Power seeks to be on the verge of becoming one of the leading corporations, with profitable investments in the utility sector, particularly focusing on Power & Water and different sources of energy. The company is driven by the confidence and experience of a joint partnership between Qatar Electricity & Water Co., Qatar Petroleum International, and Qatar Holding. Nebras Power has been established to invest in feasible and profitable large-scale power & water projects around the world. Nebras seek to expand the range of its services, and provide complete solutions for establishment of new LNG handling facilities, Water Treatment Plants, Fuel sourcing and supply ventures, making Nebras a significant player in the MENA region, South East Asia, Europe, and beyond. www.nebras-power.com
Without question the challenge in this project was the fact that the turnaround period was extremely short, in which the new blades had to be engineered, manufactured, tested and shipped to Jordan without the availability of forgings. Stork not only accepted this challenge, but our employees in cooperation with the plant’s team ensured that the work was executed within the limited time frame consistently, methodically and precise. In the end the blades were ready for pick-up a few days ahead of the already challenging plan of four and a half week.
Like every other blade that leaves our factory we are proud to commit to the highest level of blade quality in the industry. The plant management made sure that the blades were immediately installed after they have been supplied and ensured the turbine is operational again, ready to provide Jordan with the required power at the beginning of the summer season.
A wide range of technical challenges were also faced in this project, including the material selection due to the lack of forgings, special tooling required for the root milling and frequency measurements all of which had to be designed, tested and manufacture within the same timeframe.
In just a couple of weeks Stork was able to tackle all these challenges, and manufacture OEM Equivalent blades that are now in operation in yet another turbine in the world, as we have done for over 50 years.
This project, challenging as it was, is an example of a success story for Stork Turbo Blading and AES due to the tireless commitment of Stork’s employees to get the job done, and the dedication to speed and results of the AES team who visited Stork several times during the manufacturing process. Our blading team worked 24/7 to get the blades ready in this short time span, while our Engineers made sure that the production methods were technically approved. After the supply the turbine became operational again in no-time thanks to the plant’s team.
The commitment of all parties involved was perhaps most noticeable and truly unique.
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