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: salescz@brush.eu

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