siemens.com/field-service-fossil

Siemens Field Service

Service Innovations with On-Site Machining

When talking about optimal service, we generally look at it from the customer’s perspective. What is the fastest way to get your plant up and running again? Which service benefits you the most? How can costs be reduced? What will improve the reliability of your plant?

As a leading technology company, we can provide the right answers to these questions. And one of the most advanced answers is: Siemens On-Site Machining.

On-Site Machining helps you reach your goals faster

Repair time

On-Site Machining

Machining

Time savings

Factory Repair

Disassembly

Shipping

Machining

Reassembly

2

Providing optimal support for your plant in any situationAs an OEM, we are highly familiar with the specific challenges our customers are facing – such as the need for high availability, long service intervals, shortest possible repair times as well as costs. This is precisely where our cutting edge can play a key role. It bundles our expertise in cutting tech-nologies, auto mation, and drive tech-nology in innovative service solutions. On-Site Machining offers you a com-prehensive portfolio of mobile machine tools for highly complex, time-critical machining operations on gas and steam turbines as well as generators in your power plant. On-Site Machining saves valuable time for transports – and you are ideally equipped to deal with any possible findings, and maintain or reduce planned downtimes of your plant.

Your benefits• More cost effective due to

shorter repair times• No time-consuming transports,

no transport risk• Repairs within the critical path

of your plant downtime• Worldwide service with

state-of-the-art technology

Either way, top quality is always assured!Whether you decide to use On-Site Machining at your plant or you decide to remove and transport your compo-nents to a Siemens factory, the quality of the machining is identical. You should simply choose the service that offers you the greatest benefits.

It’s always better to be on the safe sideWe regard occupational health and safety as our top priority. This becomes even more important as we will work closely with your team on-site during service deployments. This is why we not only comply with all EHS regula-tions, which goes without saying, but also consistently integrate your employees into our safety concept.

Our safety concept includes the use of state-of-the-art technology, such as a machining environment monitored by laser scanners to ensure the maxi-mum level of safety.

3

Manufacturer quality needs manufacturing experience

Service on turbines and genera-tors is on highly complex tech-nical systems and large masses that have to be moved with maximum precision. In concrete terms this refers to hundreds of tons of steel and a level of precision down to just a few hundreds of a millimeter.

This kind of quality cannot be achieved with standard solutions.

Innovative machining of casings• Diameter machining of steam turbine and gas turbine

compressor casings• Reworking of operation-related effects of aging,

such as erosion• Piercing of new shroud grooves, machining of contact

surfaces• Restoration of optimal flow behavior• Precise control thanks to cutting-edge CNC technology• Siemens internal turning units for all machining sizes

4

Our solution: innovative, mobile machine conceptsOur technological edge begins where we leave standard solutions behind. We have been working with On-Site Machining for decades and have made successions of proprietary develop-ments in this field. This approach is crucial as we continue to meet ever-increasing precision and quality requirements.

Based on our comprehensive expertise in development, design, commission-ing and execution of CNC On-site Machining you will benefit from the solution that we can offer tailored to your need.

Quality is not left to chance …… but is rather the result of planning that corresponds to implementation. Our knowledge regarding the quality of the machining is reflected in a modular offering for On-Site Machining. That is why extensive consultation is part of our offering: What level of precision should the machining have? Which machine is the right one to achieve that? What benefits would be offered by the next-higher level of machining quality? We are able to answer these questions for you with the detailed knowledge possessed by the manufacturer of the components as well as of the machine tools.

Our experience pays offIn the end, our On-site Machining is based on a century of experience in manufacturing of reliable power plant components – and of the required machine tools. This knowledge is the basis of machining concepts that precisely meet the requirements of our customers.

Our service offerings include high-end machine tools as well as smart concepts that are tailored to your indi vidual budget and precision requirements.

5

Reliability and perfor-mance is at the heart of On-Site Machining

Even the best machining tools can only work as good as they are being operated. Our On-site Machining specialists are the experts in mobile machining and are optimally trained for the machining equipment which we also have developed.

6

This is what you can expect from usFor us, reliability begins with precision. And with the sense of responsibility that comes with offering you the best possible service wherever you may need us. We believe reliability also means working with proven, clearly structured processes and checking our improvements at regular milestones – all with the objective of getting your plant up and running again faster than ever.

Top performance requires first-rate service …Turbines and generators run with greater safety and efficiency when they are maintained on a regular basis. You benefit from what makes our service truly first-rate – from every-thing working perfectly together. It begins with our employees, who

we train on an ongoing basis, and the experience they gain in their daily work – experience which is then incorporated back into the develop-ment of our machines. It continues with a sophisticated measurement technology that allows us to define the precision requirements of our work with ever-increasing accuracy. Finally, it is the machines that we equip with our own innovative technology: These machines make it possible for us to reach this high level of precision on-site at your plant.

… and a strong, international networkWith On-Site Machining, you can rely on an experienced partner even when you have an unexpected need for our services or require them following a finding report. Thanks to our exten-

sive fleet experience we are prepared for anything and can optimally plan and implement assignments even at short notice. In the end, we need a team of specialists at your plant who are a perfect match for the job. And we have to initiate preparatory mea-sures, select the right machines and shipping agents, and take care of any customs formalities. Despite the organizational work this involves, this approach ultimately results in time savings that will directly help reduce the downtime of your plant.

Advanced rotor machining• Premium-quality machining of complex

rotor geometries• Use when needed in acute diagnostics

situations or as a planned measure• Restoration of the original contours of

inflows, bearings, blade grooves, etc.• Laser-supported implementation• Internal and external machining of rotors,

e.g. short ring modification

7

On-Site Machining – part of a comprehensive service offering

Planning and improvementAny complex On-Site Machining operation starts with precise measurements and coordination with Siemens Service Engineering. Based on OEM expertise, Service Engineering uses the measurement data and other examination results to develop a suitable machining strategy. This includes improvements or increases in performance that can be achieved through machining operations conducted on your equipment. We discuss the possibilities with you on-site and work with you to develop concrete specifications regarding further actions.

Optimal preparation, fast serviceThese specifications take into consideration any special machining conditions at your site, such as the fact that multiple measures may need to take place simultane-ously and possibly within a confined space. Through ongoing optimization, we’ve been able to reduce machining times on-site by approximately one third, and we are continuously working to achieve further improvements. To save time, our machine tools for interior contours are equipped with dual tool arms. Naturally, we continually review the machining quality and progress to ensure that everything goes as planned.

A closed loop systemThe results from practical applications are also made available to Service Engineering so they can use them for comprehensive analyses. The objective is the con-tinuous improvement of machining processes, machine control, and the programming of complex machining cycles. For this, the data from actual operations pro-vides valuable information. With On-Site Machining, you benefit from a technological edge of several years.

For you, On-Site Machining means greater performance and, above all else, innovative machining possibilities that you will not find anywhere else.

On-Site Machining cannot be implemented in isolation from other services, such as non-de-structive testing, welding technologies, assembly and commissioning.

As with all our services, it is based on a compre-hensive analysis and preparation conducted by Siemens Service Engineering for the spe-cific service measure.

8

Advanced valve repair• Repair of wear and erosion in valve seats • High precision turning and grinding• Machining of multiple affected areas

in a single operation• Low maintenance costs instead of

expensive valve replacement• Shorter downtimes and cost savings

9

Smart data is on your side

Measure what can be measuredDigitalization is a crucial success factor for On-Site Machining because it helps us to achieve true technolo gical ad-vances in many areas. One important field is measurement technology, which is opening up completely new possibilities in measurement and in the machining of components thanks to tools such as laser trackers and laser scanners. Today we can perform three- dimensional measurements of com-plex components and compare in detail any possible changes against the original data. In On-Site Machining, we are able to restore the original

contour even in the case of complex special geometries.

Digitalization as the next logical stepPaperless manufacturing, a pioneering technology used in many industries, is now being used in Siemens Field Service as well. With paperless service, the machining data is developed directly from the 3D engineering data. With this step, we can further reduce machining time in order to minimize downtimes.

We know that technology requires the right founda-tion of data to enable further advances. Today it is primarily digitalization in industrial production that is opening up new possibilities for us.

In conjunction with new measurement techniques, we can now offer you complex 3D machining operations with a level of precision that was unthinkable just a short time ago.

10

Combining and intelligently evaluating dataThe high quality of present-day measurement results not only make it easier to restore original contours, they offer diverse possibilities and approaches for technological improve-ments. This is especially true in light of the fact that, as an OEM, we have hundreds of similar machines in opera-tion worldwide that provide us with data for extensive analysis. In addition, we can draw upon the measurement values from different services, such as vibration analyses from the area of predictive maintenance, and compare

them to the measured geometry data. The knowledge gained from such comparisons is incorporated in our product development as well as in the ongoing development of our machine tools.

That is On-Site Machining from Siemens.

11

Siemens Field Service WorldwideThere wherever you need us

Our comprehensive services include measures such as:

Component condition assessment• Visual inspections• Videoscopes• On-site assessment and analyses• Non-destructive testing (NDT)• FAST Gen™ generator inspections• Alignment control• Clearances wear and tear inspections• Vibration monitoring• Functional and electrical analyses• Foundation shift measurements

and monitoring• Failure and root cause analysis• Online and archive data review and evaluations• Lifetime assessments (LTA)• Lifetime extensions (LTE)

Component repair• Welding and heat treatment• Mechanical work• Parts exchange• Special tool applications• Shaft alignment and balancing

On-Site Machining solutions• Innovative machining of casings• Cutting edge technology in rotor machining• Advanced valve repair • Effective smart data usage

Siemens Field Service WorldwideThere wherever you need us

Siemens Field Service offers comprehensive services for complete power plant installations, gas and steam turbines as well as generators. We work with state-of-the-art diagnosis and fault-detection systems as well as Siemens Service Engineering in order to improve efficiency, reduce emissions, and guarantee availability over the entire lifecycle of the power plant. With our strategically positioned branches in many coun-tries of the world, we are always close to our customers so that we can implement project- and customer-specific field service solutions at any time.

Benefit from the expertise and experience of an industry leader• Manufacturer and specialist knowledge based

on over 165 years of experience• Products and services from the OEM• Construction and commissioning

of new power plants worldwide• Hundreds of inspections and maintenance

annually

Global presence• Local in more than 190 countries• 290 production sites and factories

in more than 40 countries• 19 field service branches worldwide

to be close to our customers

Highest quality standards and skilled experts• Preparation of more than 300 project plans

annually• Integrated quality management system

certified to DIN IS0 9001 • Over 4,500 qualified field service engineers

and technicians worldwide

Published by Siemens AG 2016

Power Generation Services Division Freyeslebenstrasse 1 91058 Erlangen, Germany

E-mail: field-service-marketing.energy@siemens.com

Field Service Marketing Region Europe Power Generation Services Huttenstrasse 12 10553 Berlin, Germany

For more information, please contact our Customer Support Center. Phone: +49 180 524 70 00 (Charges depending on provider) E-mail: support.energy@siemens.com

Article No. PSPG-B10092-01-7600 Printed in Germany Dispo 34805 TH 288-160914 BR 1016Subject to changes and errors. The information given in this document only contains general descriptions and/or performance features which may not always specifically reflect those described, or which may undergo modification in the course of further development of the products. The requested performance features are binding only when they are expressly agreed upon in the concluded contract.

Siemens Field Service