Energy is a permanently fluctuating market, according to the technological, political and economic developments it encounters.
In this context, the energy industry must anticipate, and can even sometimes be at the origin of technological innovations.
Laserco has therefore developed a family of products and services, PowerClad, particularly suited to the challenges of high-level maintenance of turbomachinery (Steam Turbines, Industrial Gas Turbines, Hydroelectric Turbines) and generators, of all sizes and powers.
Whether increasing the performance of certain surfaces by cladding alloys on CrMoV bases for rotors, discs, shafts and diaphragms, or depositing on Nickel-based superalloys, incorporating Chrome, Cobalt and Rhenium on the blades, Laserco offers effective answers in terms of turbine manufacturing, maintenance and reconstruction.
Furthermore, the precision required for the reconstruction of rotor shafts, as well as their rectification and balancing, is a valuable support for generator and turbine maintainers.”
The blades and other components of steam turbines are not exposed to such high temperatures as those of gas turbines, but they must withstand operation with two-phase fluid.
The high content of water droplets can cause rapid blade impact and erosion, which occurs when condensed water is sprayed onto the blades. Furthermore, these blades must be (due to the high specific volume of vapor) geometrically very long, which induces enormous centrifugal forces during operation.
As a result, turbine blades are stressed by centrifugal force (turbine stages can spin at tens of thousands of RPMs, but typically at 1800 rpm) and stresses. fluids that can cause rupture, yield or creep failures.
Laserco develops alloy deposition processes to reconstruct and protect the leading edges of the blades – but also the lower surfaces and upper surfaces – against the erosion of the two-phase medium, coupled with high temperatures. With TurboClad, Laserco integrates the needs of steam turbine manufacturers and maintainers to offer dedicated solutions for repairing and upgrading shafts, blades and many other components.
With temperatures above 1450°C at the combustion chamber outlet, the most exposed components to temperature, acidity, pressure, etc are the rotor and stator turbine blades. On the rotor, these are also closed on the outer ring by an abradable seal applied by plasma or HVOF.
The application of Nickel, Chrome and Molybdenum-based alloys, as well as diamond pellets on the blades, but also the surfacing, machining and grinding of the turbine shafts improve the performance of gas turbines . In terms of maintenance, rebuilding and improving components subjected to such harsh environmental conditions keeps operating costs at acceptable levels.
Hydroelectric turbines have much lower rotational speeds than thermodynamic turbines, but are fully immersed.
In addition to corrosion, cavitation regularly damages all blade components; leading, bottom and top edges, and trailing edges.
Laserco has developed significant expertise in the treatment of hydroelectric turbine blades, taking into account the environment in which they evolve, but also their large size and weight, which require complex handling equipment.
Generators are another crucial component of power generation, whose operational characteristics allow no approximation in terms of functioning.
At the centre of rotors weighing several tonnes and rotating rapidly to extremely tight tolerances, the rotating shafts are subject to significant stresses and must maintain their mechanical and dimensional integrity throughout their operational life.
For several years, Laserco has developed processes and means to optimise the repair of rotor shafts, from pre-machining to grinding. Keyways and various bearing surfaces can be rebuilt or modified with great precision.
