Siemens Field Service
Service Innovations
with On-Site Machining
siemens.com/field-service-fossil
On-Site Machining
helps you reach your
goals faster
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.
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Providing optimal support for your plant
in any situation
As 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 technologies, auto­mation, and drive
technology in innovative service solutions. On-Site
Machining offers you a comprehensive 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
components 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 side
We 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 regulations, 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 maximum level of safety.
Repair time
Factory Repair
On-Site Machining
Disassembly
Shipping
Machining
Machining
Reassembly
Time savings
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Manufacturer quality
needs manufacturing
experience
Service on turbines and generators is on highly complex
technical 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 hundredths of a millimeter.
This kind of quality cannot be achieved with standard
solutions.
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Our solution: innovative, mobile machine concepts
Our 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 developments 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, commissioning and execution of CNC On-site
Machining you will benefit from the solution that we
can offer tailored to your need.
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
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 nexthigher 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 off
In 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
indi­vidual budget and precision requirements.
5
Reliability and
performance 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.
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This is what you can expect from us
For 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 everything 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 development 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 network
With 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 extensive 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 measures,
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
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On-Site Machining –
part of a comprehensive
service offering
On-Site Machining cannot be implemented in isolation
from other services, such as non-destructive testing,
welding technologies, assembly and commissioning.
As with all our services, it is based on a comprehensive
analysis and preparation conducted by Siemens Service
Engineering for the specific service measure.
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Planning and improvement
Any 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.
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
Optimal preparation, fast service
These specifications take into consideration any special
machining conditions at your site, such as the fact that
multiple measures may need to take place simultaneously
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 system
The 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 provides
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.
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Smart data
is on your side
We know that technology requires the right foundation
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.
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Measure what can be measured
Digitalization is a crucial success factor for On-Site
Machining because it helps us to achieve true technolo­
gical advances 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 threedimensional measurements of complex 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 step
Paperless 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.
Combining and intelligently evaluating data
The high quality of present-day measurement results not
only make it easier to restore original contours, they offer
diverse possibilities and approaches for technological
improvements. This is especially true in light of the fact
that, as an OEM, we have hundreds of similar machines in
operation 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.
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Siemens Field
Service Worldwide
There 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 Worldwide
There 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 countries 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 and copyright © 2015:
Siemens AG
Freyeslebenstrasse 1
91058 Erlangen, Germany
Field Service Marketing
Region Europe Power Generation Services
Huttenstrasse 12
10553 Berlin, Germany
E-mail: field-service-marketing.energy@siemens.com
Siemens Energy, Inc.
4400 Alafaya Trail
Orlando, FL 32826-2399, USA
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
Power Generation Services
Article No. PSPG-B10092-00-4A00
Printed in Germany
Dispo 34805
TH 288-150254 | WS | 09151.0
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of Siemens AG, its affiliates, or their respective owners.
Subject to change without prior notice.
The information in this document contains general descriptions
of the technical options available, which may not apply in all cases.
The required technical options should therefore be specified in
the contract.