COMPANY PRESENTATIONCIMTAS PRESICION MACHINING Cap ab ilities @ a Glance Machining: 16 x 5-axis + 4...
Transcript of COMPANY PRESENTATIONCIMTAS PRESICION MACHINING Cap ab ilities @ a Glance Machining: 16 x 5-axis + 4...
C O M P A N Y P R E S E N T A T I O N
C I M T A S P R E C I S I O N M A C H I N I N G
POWER AVIATION OIL & GAS
C o n t e n t
• About Us
• Cimtas Precision Machining
• Cimtas Group
• ENKA
• Special Process Capabilities
• Electron Beam Welding
• Additive & Laser Welding
• Heat Treatment & Brazing
• Surface Treatment & Coating
• Cutting & Trimming
• Inspection & Testing Capabilities
• Metallurgical Capabilities
• Component Qualifications
• Product Line Focus – Aviation
• Digital/Paperless Manufacturing
• Certificates
• Awards
• Cimtas Precision Machining
• Differentiators
• Capabilities @ a Glance
• Manufacturing Capabilities
• Machining
• Forming
• Conventional Welding
C I M T A S P R E C I S I O N M A C H I N I N G M i l e s t o n e s
• Business Lines : Power – Aviation – Oil & Gas
• 12,000 Sqm (129,166 SQ FT) Fenced Yard
• 11,400 Sqm (121,700 SQ FT) Covered Shop Floor
• Located in Bursa FTZ/Turkey I 2 hrs /100 km from Istanbul & 2 km from 4 International Deep Sea Ports
C I M T A S P R E C I S I O N M A C H I N I N G A b o u t U s
Multiple Award Winning Manufacturer of Complex Components
Ç İ M T A Ş G R O U P G r o u p C o m p a n i e s
LSAW Pipes, Fittings & Pipe SpoolsFenced Area: 1.2M sqft & Covered Area: 710K sqftLSAW Pipe: 70K tons/year (power piping) Man.Cap.
160K tons/year (line pipe) Man.Cap.Fitting: 1K tons/year Manufacturing CapacitySpool: 42K tons/year Fabrication Capacity
Gas Turbine & Aviation Combustion PartsFenced Area 183K sqft & Covered Area: 122K sqftMulti-axis CNC Machining, EBW, Laser Welding, Vacuum HT & Brazing, Thermal Spray, 3D CMM
Large Fabrication, Steel Structures, HRSGs Pressure Vessels, Wind TowersFenced Area 1.8M sqft & Covered Area: 645K sqft5K t/month Fabrication Capacity
Prefabricated Piping, Module/Skid AssemblyFenced Area: 293K sqft & Covered Area: 230K sqft9K tons/year Fabrication Capacity
Powerships, Chemical/Oil Product Tankers Steel Structure, BridgesFenced Area: 2.3M sqft & Covered Area: 463K sqft35K tons/year Fabrication Capacity2 Slipways (180 x 56 m with 400 t Gantry& 60K DWT capacity)
• Founded in 1973 in Turkey & consist of 5 companies 4 in Turkey & 1 in China
• Annual Turnover $330 M 2,500 People including 350 Engineers
• Over 135,000 mt/year fabrication capacity
• Over 150,000 mt/year manufacturing capacity
E N K A P r o f i l e
• 50 Subsidiaries Operating in CIS, Asia, Middle East,
Europe, Africa & Turkey
• Over 500 Projects in 45 Countries, with $43B Value
• Turnover $3B (2017)
• Amongst the Top 100 International Construction
Contractors since 1982
• 72ⁿd in ENR International Contractors List
• More than 30,000 People
• Traded Publicly in BIST (Borsa Istanbul) with a Market
Cap of More than $7B
ENKA 1 ENKA 2 ENKA 3
Founded in 1953
Engineering & Construction
Real EstateTrade
ENKA Power
Business Lines
S A F E T Y & E N V I R O M E N T
• Zero Accident (Corporate HSE) Programme
• OHSAS regulation
• Risk Analysis & Lessons Learned
• 5S Programme
• Effective use of Energy
R E L I A B I L I T Y
• Preferred Partner
• Proprietary Privilege & Code of Conduct
• Sustainability
• On Time Delivery
• Least Total Installed Cost
• Effective use of Advanced Technology
E F F I C I E N C Y
• State-of–the–art facility
• Lean, Six Sigma & Kaizen Workshops
• Digital/Paperless Manufacturing
• Multiple Award Winner with Proven Flexibility
• Statistical Process Control
W O R L D C L A S S Q U A L I T Y
• High-tech Machinery
• Special Processes
• Multi-Metallurgy Manufacturing
• Proven Quality Assurance Systems
• Wide International Experience
• Skilled & Dynamic Personnel
C I M T A S P R E C I S I O N M A C H I N I N G D i f f e r e n t i a t o r s
C a p a b i l i t i e s @ a G l a n c e C I M T A S P R E S I C I O N M A C H I N I N G
Machining: 16 x 5-axis + 4 multi axis CNC5-Axis Turning & Milling – Vertical/ Horizontal • 6 Mazak Integrex e-TOWER 1060 V8-II• 1 Mazak Variaxis i800 & 2 Mazak Integrex i200s• 2 Mazak Integrex e-Tower 1250 V8-II & 1 Mazak FJV 60/80• 4 DMU_85 Monoblock & 1 DMU Moriseiki NLX 2500 I 700• 2 Mazak Variaxis i800 & 1 DMU_125 FD duoBlock
Special Processes• 2 EB Weld (30KW – 403ft3)• 3 Vacuum Heat Treatment & Brazing (177 ft3 )• 2 HVOF & Plasma Arc Spray• 1 Robotic Laser Cutting and Laser/TIG Welding System• 1 Shot peen & 1 Automated Grit Blasting• 1 CMT Robotic Additive Welding
Inspection & Testing • X-Ray 1 unit -200Kv• Fluorescent / Liquid Penetrant Inspection• Air Flow Inspection & Contact Ultrasonic Cleaning• Video Boroscope Inspection & 2 CMM • In-house Level I, II, III NDT personnel (SNT-TC-1A & PED 97/23,
EN 473, NAS410)• Accredited Mechanical & Metallography Lab.
(ISO/IEC 17025:2005)
Conventional Welding & Forming • Conventional Welding: Austenitic Stainless Steel (304L to 347)
| Duplex Stainless Steel Nickel Alloys (incoloy, inconel [AMS5536,AMS5542, AMS5608], Nimonic [C-263] Monel)| Alloys (P11, P92, etc)
• Forming: 3 Vertical Hydraulic Presses 197 x 138 x 177 inch –max. 2,500 tons | Hydraulic Expander Ø23,6’’-0.40’’thk. 150 tons
• 4 Roller Cylinder m/c 1,000 mm w – 1.02 inch thk | Waterjet
M a c h i n i n g
• 16 x 5-axis + 4 multi axis CNC
• Simultaneous 5-Axis Turning & Milling
(Up to 49")
• Compliance with Stringent Machining Tolerances
(+/- 0.0002")
• CAD / CAM• Esprit 2 + C + Y + B Simultaneous• Catia V5R20 • Unigraphics NX 10.0
• Mold, Fixture and Tool Design
M A N U F A C T U R I N G C A P A B I L I T I E S
F o r m i n gM A N U F A C T U R I N G C A P A B I L I T I E S
• 3 x Vertical Hydraulic Presses (1,000 2,000 and 2,500 tons with 1,000 tons Integrated Extruder)
• AutoForm and PAM-STAMP Forming Simulationfor Mold Design and Implementation
• Hydraulic Expander
(150 tons Hydraulic Pressure)
M A N U F A C T U R I N G C A P A B I L I T I E S E l e c t r o n B e a m W e l d i n g
• 1 x Steigerwald Strahltechnik
1 x Probeam Equipment
• High Vacuum Electron Beam Welding Equipment with 30 kW Beam Power
• Working Chamber Dimension (inch)
• 107 (L) x 83 (H) x 79 (W) via volume of 403 ft³
S P E C I A L P R O C E S S C A P A B I L I T I E S C o n v e n t i o n a l W e l d i n g
• 20 manual + 6 Automatic Welding Stations
• Additional Qualified Welder Pool (>100) from
Other Cimtas Locations
• Manual and Automated Welding
(GTAW, SMAW, FCAW, GMAW [STT/RMD/CMT],
SAW and PAW)
• 2,500 PQR and 6,400 WPS in Library
• IIW/EWF Certified Welding Engineers
• In-house Fit-up & Welding Operator Training Center
A d d i t i v e & L a s e r W e l d i n gS P E C I A L P R O C E S S C A P A B I L I T I E S
• Additive Welding Robot for Turbulator Build-up on Hydraulic Pressed N263 & N282 NimonicCombustion Liner Bodies
• Tailor made Robotic Laser Cutting and
Robotic Laser / TIG Welding Operations
• 6 kW Fiber Laser Power and Capable for a Power Capacity Enlargement up to 15kW
• Number of Axis : Totally 11 Axis
(6 Robotic Axis and 5 positioner axis)• 35 m³ Cell Volume with a 1,000 kg max. Weight
Of Part Loading
H e a t T r e a t m e n t & B r a z i n gS P E C I A L P R O C E S S C A P A B I L I T I E S
• 3 x Vacuum Furnaces I Certified to Class 1 as per AMS 2750
• Specially Designated for Annealing, Stress Relieving, Stabilization, Precipitation Heat Treatments & Brazing Operations
• Max. Operation Temp: 2,400°F
• Work Zone Dimension: 61 (W) x 58 (H) x 287 (L), with effective capacity of 177 ft³
• Max. Weight Of Load: 8,150 lbs and 1,450 kW
• Ar/N2 Quenching
S u r f a c e T r e a t m e n t & C o a t i n gS P E C I A L P R O C E S S C A P A B I L I T I E S
• 2 x HVOF & Plasma Arc Spray
(GE Power approved HVOF & TBC Qualifications)
• 1 x Shotpeen (Auto Dual Media Change)
• Wet Grid Blast, Tailor Made Automated GritBlasting, Glass Bead Peen
• Ultrasonic Cleaning, Alkali/Etch Cleaning,Passivation
C u t t i n g & T r i m m i n gS P E C I A L P R O C E S S C A P A B I L I T I E S
• Robotic Laser Cutting (6 kW Fiber Laser Power, 1236 ft³ Cell Volume with a 2,205 lbs Weight of Part Loading)
• 5 axis Waterjet (Max. Loading 17,600 lbs)
• Plasma Cutting
I N S P E C T I O N & T E S T I N G C A P A B I L I T I E S
• Accredited Mechanical & Metallography Laboratory(ISO/IEC 17025:2005)- Plasma test coupon evaluation- NPI cut-up & testing- Welding PQR tests
• Radiographic Particle Inspection • Magnetic Particle Inspection• Fluorescent Penetrant Inspection• Liquid Penetrant Inspection• Macro Etch Inspection• In-house Level I, II, III NDT personnel
(SNT-TC-1A & PED 97/23, EN 473 & NAS410)• CMM Dimensional Inspection • Air Flow Inspection• Contact Ultrasonic Testing• Hydrostatic Testing• Form Tracer• Positive Material Identification (PMI)• Video Boroscope Inspection
M E T A L L U R G I C A L C A P A B I L I T I E S
@ a G l a n c e
Key Assets
• Fabricated, Structural & Rotating Parts
• Expertise in Superalloys
• Concurrent Engineering Capability
• Short Lead Time from Design to Market
• Process Optimization (6 Sigma, Lean, SPC)
• Integrated Change Management
• JD Edwards Oracle ERP
N E W P R O D U C T I N T R O D U C T I O N
Engineering
• Esprit 2 + C + Y + B Simultaneous (CAM)
• Catia V5R20 (CAD)
• Unigraphics NX 10.0 (CAD)
• PAM-STAMP & AutoForm for Mold Design & Optimization
• Minitab
• PMP Certified Project Managers
NPI Flow
C O M P O N E N T Q U A L I F I C A T I O N S
Combustion Casing9FA Fwd/Aft
Combustion Casing
9FA XD5 Fwd/Aft
7FA.05 Fwd/Aft
Combustion Casing
6FA Fwd/Aft
7F FLEX PH1 Fwd/Aft
6F.01 (6C) Fwd/Aft
9E Std Aft
Combustion Casing
7FA.05 Fwd/Aft (New)
7F FLEX PH2 Fwd/Aft
7HA.02 OUTER CapAssembly
7HA.01.02
End Cover
9FA, 9FA XD5
7F FLEX PH2
Liner
7FLEX PH2
Closed
On-going
6
13
23
2017-2018
Combustion Casing
501F
6F.03 Fwd/Aft, 9F.05 Fwd/Aft
End Cover
7HA.02, 6F.03, 9F.05
Liner
9F.03
9F.04, 6F.03, 9F.05, 7F.04, 7F.03
Transition Piece
9FA,
7HA Unibody, 7E,
7FA.04, 7HA.03, 6B, 6F.01
Aero-Piping
LM900 Oil Sump
2
• *Required processes match with the existing capabilities from Energy Business
P R O D U C T L I N E F O C U S – A V I A T I O N
Rotating seal Rotating seal Air duct Combustion casing
• Parts in Production
• MS5001 Transition Pieces
• LM9000 Oil SUMP Case piping
• Part Family Focus
• Cases
• Bearing Housing
• Wishbone
• HPT / LPT Shafts
• LPT Spacers
• Mounts
• Spinner Support
• Shroud Support
• Fab Supports
• Bellcranks
• Air Ducts
• Fan Frame
D I G I T A L / P A P E R L E S S M A N U F A C T U R I N G
• Collect• Sensors, Automation Systems
• Analyze• Descriptive Analytics, Diagnostic,
Analytics, Machine Learning, PredictiveAnalytics and Prescriptive Analytics
• Act• Real-time Stream Processing,
Trigger Events / Alerts Based on Complex or Dynamic Criteria, Interface to LocalSystems, Collaborative ManufacturingEnvironment
• Zero Human Touch• Minimized Operational Time Fully Integrated
Engineering and Manufacturing Systems• Real-time Production Monitoring• Performance, Quality, Availability,
OEE Analysis• Easily Configured• Improved Quality• Machine Learning
Operator Productivity Dashboard
Mobile & Web User Interfaces
Anomoly Defection, Alarms, Predictive Maintenace
Paperless Manufacturing
C E R T I F I C A T E S
I S O 1 4 0 0 1 : 2 0 1 5 I S O 1 8 0 0 1 : 2 0 0 7 I S O 9 0 0 1 : 2 0 1 5 I S O 2 7 0 0 1 : 2 0 1 3
T E I T A I A S E N : 9 1 0 0
A W A R D S
GE Power Strategic Partner
2015
GE Power Overall Partnership
2017
Best Digital ManufacturingOperational Excellence Project Of the Year
by IDC-Turkey2017
Cimtas Precision Machining Awards
Cimtas Group Awards