Power Generation

As utility deregulation creates more opportunities and greater competition for the power generation industry, EBTEC is ready with solutions. We have the equipment, experience, and expertise to help power producers improve the operating efficiency of steam and gas turbines, as well as their bottom lines.

Power generator manufacturers come to EBTEC for turbine upgrades, typically requiring a redesign of the diaphragms. Customers simply place an order for a turbine diaphragm and we manufacture it to specification. The substantial gains in operating efficiency - one customer noted a 33% gain - provide rapid payback.

Our new 6000-square-foot work space is dedicated to the fabrication of larger items such as complete turbine diaphragms. EBTEC's abilities with high energy beam processes, coupled with our new conventional machining capabilities, eliminate long lead times and multiple source contracting. All operations from simple machining to complex, high energy beam services are controlled and managed in our newly expanded facility.

EBTEC's experience refurbishing overhauled blades and vanes provides reliable subcontract results. When refurbishing cooling holes through laser drilling, precision control of hole size is attained through air flow technology.

Electron Beam Welding

• ASME section IX qualified
• Deep weld penetration and minimal distortion
• Ideal for turbine diaphragms
• Three-inch depth of penetration on cross sections 3/8" wide
• High power EB welding machine with the largest chamber on the East Coast. Accommodates work pieces up to 10 feet in diameter
• Diaphragm assemblies
• Power turbine shafts
• Blades and vanes
• Turbine case flanges and repairs

More information on Electron Beam Welding

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Abrasive Waterjet Cutting

• Vane profile for cage assembly
• Flat sheet cutting for component detail
• Diaphragm assemblies (cages)
• Strainers - steam filter components
• Full 5-axis capabilities
• Complex & simple geometrics

More information on Abrasive Waterjet Cutting

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Laser Cutting & Drilling

The use of laser technology substantially reduces the manufacturing costs of many components.

• Thin cross sections, inner and outer band segments for diaphragms
• Blades
• Vanes
• Overhauled and new components
• Strainers
• Tip caps and metering plates

More information on Laser Cutting
More information on Laser Drilling

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Ultrasonic Testing

Many of our customers require non-destructive testing for their components after processing. Ultrasonic testing in-house facilitates their needs for rapid service and turn times.

• Inspection of weld integrity

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Heat Treating

With a vacuum furnace and three additional atmosphere furnaces, EBTEC can meet most needs for individual parts or production runs.

• In-house stress relief
• Brazing capabilities
• Annealing
• Aging

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Certified Flow Checking

EBTEC can confirm the exact correlation between air flow and hole size, a crucial process and quality control issue in many turbine engine components on in-house air flow equipment.

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Electron Beam Welding Equipment
(total of 12 EB Welding Machines)

 

Wentgate 555
• 60kV 6kw
• height 24"
• width 24"
• length 24"

Hamilton Standard 194
• 150kV 7.5 kw
• height 36"
• width 36"
• length 52"

Hamilton Standard 308
• 150kV 25kw
• height 56"
• width 56"
• length 108"

Hamilton Standard 308-2
• 150kV 25kw
• height 110"
• width 136"
• length 144"

Hamilton Standard 177
• 150kV 6kw
• height 30"
• width 23"
• length 60"

Hamilton Standard 263
• 150kV 7.5kw
• height 56"
• width 56"
• length 108"

Wentgate 921
• 60kV 3kw
• height 24"
• width 24"
• length 24"

Hamilton Standard 603
• 150kV 7.5kw
• height 45"
• width 36"
• length 53"

Hamilton Standard 379
• 150kV 7.5kw
• height 36"
• width 36"
• length 52"

Wentgate 976 Shuttle System (2)
• 60kV 2.5kw
• height 12"
• width 12"
• length 12"

Sciaky
• 60kV 30kw
• height 78"
• width 68"
• length 68"

 

 

 

Abrasive Waterjet Equipment

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PaR Systems 5-Axis Abrasive Waterjet
• 55,000 PSI
• X Axis 10'2"
• Y Axis 6'2"
• Z Axis 2'0"

 

Laser Machining Equipment
(total of 16 Laser Machines)

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Convergent Energy
Ultimate Arrow

1700 watt CO2
• Aerotech U620 6-Axis Control
• X axis 36"
• Y Axis 42"
• Z Axis 10"
• Tilt Rotary 20"

Raytheon SS500
400 watt Nd:YAG
• Aerotech U620 6-Axis Control
• X Axis 72"
• Y Axis 36"
• Z Axis 32"
• Tilt Rotary 20"

Aurora P50
250 watt Nd:YAG
• Aerotech U620 6-Axis Control
• X Axis 60"
• Y Axis 36"
• Z Axis 24"
• Tilt Rotary 20"

Raytheon SS500
400 watt Nd:YAG
• Aerotech U16 6-Axis Control
• X Axis 60"
• Y Axis 36"
• Z Axis 24"

Control CLC-480
400 watt Nd:YAG
• Allen Bradley 8200 6-Axis Control
• X Axis 24"
• Y Axis 18"
• Z Axis 18"
• Tilt Rotary 16" Motorized

Raytheon SS500
400 watt Nd:YAG
• Aerotech U650 6-Axis Control
• X Axis 36"
• Y Axis 24"
• Z Axis 24"
• Rotary 8"

Control CLC-480
400 watt Nd:YAG
• Aerotech U16 6-Axis Control
• X Axis 48"
• Y Axis 36"
• Z Axis 24"
• Tilt Rotary20"

ILM Series 5000
800 watt Nd:YAG
• Cincinnati Milicron Control
• X Axis 120"
• Y Axis 60"
• Z Axis 3"
• Tilt Rotary 20"

Raytheon SS500
400 watt Nd:YAG
• Aerotech U620 6-Axis Control
• X Axis 60"
• Y Axis 18"
• Z Axis 24"
• Tilt Rotary 20"

Lasag
500 watt Nd:YAG
• Tri Sigma 8352 Control
• X Axis 46"
• Y Axis 40"
• Z Axis 21"

Raytheon SS500
400 watt Nd:YAG
• Aerotech U16 3-Axis Control
• X Axis 24"
• Y Axis 16"
• Z Axis 12"
• Tilt Rotary 20"

Lumonics Model J-K MS330
350 watt Nd:YAG
• Bandit 1 6-Axis Control
• X Axis 12"
• Y Axis 12"
• Z Axis 18"
• Tilt Rotary 12"

Raytheon SS500
400 watt Nd:YAG
• Aerotech U620 6-Axis Control
• X Axis 72"
• Y Axis 36"
• Z Axis 32"
• Tilt Rotary 20" Motorized

Lumonics Model J-K MS830
400 watt Nd:YAG
• Aerotech U16 6-Axis Control
• X Axis 24"
• Y Axis 16"
• Z Axis 4"
• Rotary Tilt Chuck 4" Motorized

Raytheon SS500
400 watt Nd:YAG
• Aerotech U620 6-Axis Control
• X Axis 72"
• Y Axis 36"
• Z Axis 32"
• Tilt Rotary 16" Motorized

Lumonics Photon VFA600
600 watt CO2
• Aerotech U16 6-Axis Control
• X Axis 42"
• Y Axis 18"
• Z Axis 18"
• Tilt Rotary 20"

 

 

Engineering Department Equipment

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• 2-axis 'E' size digitizer
• 'E' size plotter
• X86 Family 6 Model P-3 CAD/CAM workstation (4)
(the above workstations have the ability to handle DXF, CADL, NFL, ASCII, IGES, UDA-FS, UNISURF & SPAC)
• MasterCam®, AutoCAD®, SurfCam®
• Micro Film reader

 

 

Quality Control Equipment

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• C.M.M. Brown & Sharpe S/N581-200-108
• Optical Comparator (OOP) 30"
• Digi-Magic Height Gages (Mitutoyo) 18" x 24" (2)
• Rockwell Hardness Tester (Wilson)
• Comparator Gage (Leitz)
• Microhardness Tester (Leitz)
• Hite-icator (Brown & Sharpe)
• Leak Detectors (Varian) 10-9 cc/sec. (2)
• Surface Plates 4" x 6" x 8" (2)
• Micro Flat 2" x 3"
• Air Flow Test Stand 3 lbs./sec. (2)
• Metallograph (Unitron) 500X
• Mounting Press (Buehler)
• Mirco Hite Brown & Sharpe
• Cutter-Metallurgical (Buehler)
• Polishers-Metallurgical (Buehler) (4)
• Master Blocks (Mitutoyo) Traceable to NBS
• Master Gage Pins .011" thru .625"
• Radiation Survey Meters (Tracerlab) (2)
• Rotary Table (Hoffman)
• SPC data collector
• Vernier calipers to 48"
• Optical comparator 12"
• X-ray film viewer
• Various hand-held measuring equipment

 

 

Heat Treating

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• Abar Ipsen vacuum furnace 48" x 48" - 2 Bar
• Blue M furnace 36" x 60" x 30" 900°F
• Blue M furnace 18" x 19" x 15" 550°F
• Cress oven 12" x 8" 2250°F
• 50-low cryogenic unit Model PR 120 (7 cubic feet)

EDM Equipment

 

Mitek 120 Amp
• X Axis 20"
• Y Axis 16"
• Z Axis 21"
• Tank 46" x 27" x 17"

Belmont ZNC 75 Amp
• X Axis 17"
• Y Axis 15"
• Z Axis 19"
• Tank 47" x 27" x 17"

 

 

Machine Shop & General Support Equipment

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• Black and Webster resistance tackers (2)
• P and H Tig Welder
• Demagnetizer 36L x 29W x 24H
• Supermax vertical mills (1)
• Bridgeport vertical mills (3)
• Trinco sand blaster 48" x 48" x 60"
• Okuma engine lathe 20" x 58"
• Lion engine lathe 33" x 60"
• Lion engine lathe 36" x 60"
• Dorries CT 180 VTL 63"
• DeVlieg 3H-72 Horizontal jig mill 35" x 72" x 48"
• Colchester engine lathe 13" x 48"
• Colchester engine lathe 15" x 52"
• DoAll band saw
• Kyson band saw
• Smith oxyacetylene torch
• Dumore tool post grinder
• No. 0 arbor press 3.5" throat
• KR Wilson hydraulic press 60 ton
• Vaqua wet blast 30" x 30" x 18"
• Phillips degreaser 48" x 72" x 48"
• Trak K-4 2-axis CNC knee mill
• Trak DPM220 3-axis CNC vertical mill