Welcome to GE Wuhan Boiler
Company Ltd.
CHEN Chaoming
Imagination at work
GE Proprietary Information—Class III (Confidential)
Export Controlled—U.S. Government approval is required
prior to export from the U.S., re-export from a third country,
or release to a foreign national wherever located.
STEAM POWER SYSTEMS | FROM GE
Emergency Evacuation – Office Building
We are
here
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访客安全须知
Safety Guidance for Shop Tour
• 在您参观工厂过程中必须由WBC人员全程陪同。
The shop tour shall be accompanied by WBC personnel.
• 在生产现场，必须穿安全鞋和戴安全眼镜。
Always wear safety shoes and safety glasses.
• 在车间内请严格遵守安全警示标志和公司要求，严禁随意跨越警示线。
Obey all cautions and instructions, and never cross the warning line.
• 在车间内请沿绿色通道行走，并经由侧面的人员通道门出入厂房。
Walk along the green gangway, and always use the side personnel exit instead of the vehicle doors.
• 禁止随意触摸设备的旋转部分或高温物体的表面。
Never touch hot product or rotating equipment.
• 严禁在吊物下自由行走或停留。
Never stand or walk under any suspended loads.
• 为了避免眼部伤害，请不要直视电焊弧光。
Never stare at the welding work to avoid radiation burns to your eyes.
• 仅在指定区域使用手机且不超过3分钟。
Use mobile phone only in designated area no more than 3 minutes.
• 厂区内禁止拍摄及录影。
Photography and/or video are not allowed.
• 除吸烟点及办公楼指定区域外，公司内部禁止吸烟。
Smoking is prohibited except the smoking points and designated area in the Office Building.
• 垃圾应分类放入指定垃圾桶内。
Wastes should be disposed in designated containers.
© 2015 General Electric Company - All rights reserved
STEAM POWER SYSTEMS | FROM GE
Agenda
通用电气锅炉业务简介
Profile of GE SPS Boiler
通用电气武汉锅炉股份有限公司简介
Profile of GE Wuhan Boiler Company Ltd.
通用电气武锅先进的技术
GE Wuhan Boiler Advanced Technology
通用电气武锅先进的管理
GE Wuhan Boiler Advanced Management
© 2015 General Electric Company - All rights reserved
4
通用电气锅炉业务简介
Profile of GE SPS Boiler
STEAM POWER SYSTEMS | FROM GE
蒸汽发电系统
Steam Power System
Auxiliaries
辅机
Boilers 锅炉
Steam Turbines
蒸汽轮机
Power Plants
电厂
ECS
环境控制系统
No 1 Steam Component
Supplier
排名第一的蒸汽部件供应商
Generators
发电机
CCS
二氧化碳捕捉与储存
© 2015 General Electric Company - All rights reserved
STEAM POWER SYSTEMS | FROM GE
GE Boiler
USA/
Windsor (CE)
Germany/Stuttgart
(EVT)
India/Delhi,
Shahabad,
Durgapur
China/
Wuhan
（WBC）
Singapore
符号
锅炉总部(新加坡) Boiler Headquarter
业务中心 Execution Center
新建项目制造基地 Manufacturing base for new build projects
研发基地 Research Center
© 2015 General Electric Company - All rights reserved
STEAM POWER SYSTEMS | FROM GE
BOILER “FAMILY TREE”
Alstom Boiler Deutschland
GmbH (EVT)
Stuttgart, Germany
2011
2007
2000
1999
1998
1989
1970
1921
Power Inc.
(CombuAlstomstion
Engineering)
Alstom India Ltd.
Wuhan Boiler
Company Ltd.
Windsor, CT, USA
New Delhi, India
Wuhan China
ALSTOM Boiler
Deutschland GmbH
2000
Alstom Power Inc.
Alstom Power
Systems GmbH
1999
ABB-ALSTOM Power
ALSTOM Power Boiler
GmbH
ABB ALSTOM Power
ALSTOM Energy
Systems GmbH
GEC ALSTHOM
EVT Energie-und
Verfahrenstechnik
GmbH
1990
ABB Power System
1953
Combustion
Engineering
1948
1912
Combustion
EngineeringSuperheater Inc
Combustion
Engineering (CE)
2012
ALSTOM India Limited
2002
ALSTOM Projects India Ltd
2000
ALSTOM Power India
Limited
1999
ABB ALSTOM POWER INDIA
LIMITED
1992
ASEA BROWN BOVERI
MANAGEMENT LIMITED
1963
Boiler/Mill facility
established in Shahabad
1959
Power Boilers facility
established in Durgapur
CE
KSG
KohlenscheidungsGesellschaft GmbH
EVT
© 2015 General Electric Company - All rights reserved
ABL
2007
Alstom Wuhan Boiler
Company Ltd.
1997
Wuhan Boiler
Company Limited.
1995
Wuhan Boiler Group
Co., Ltd.
1954
Wuhan Boiler Factory
WBC
通用电气武锅简介
Profile of GE Wuhan Boiler
Company Ltd.
STEAM POWER SYSTEMS | FROM GE
Introduction to GE WBC
WBC has more than 60 years of experience in designing and
making boilers.
2015
2009
2007
1998
1958
1953
Preparati
on for
establishment of
Wuguo
Wuhan
Boiler
Group
ALSTOM
WBC
Co.,
Ltd.
Relocated
to
current
site
Joined
GE
Power
Wuhan
Boiler
Works
Gross land area: 463,000 m2 Covered area: 173,000m2 Employees: ~2000 Annul Capacity: 4500 MW.
Current shares: Non-tradable ACL 51% and Wuhan Boiler Group 6.9%; Tradable 42.1% by minority shareholders
© 2015 General Electric Company - All rights reserved
STEAM POWER SYSTEMS | FROM GE
Wuhan Boiler Organization Chart
Effective from Nov 24, 2016
General Manager
CHEN Chaoming
Finance
FENG Zheng
Human Resource
Jenny ZHANG
Legal & Contract
YANG Ning
Project
Management
ZUO Zhihui
Engineering
WANG Xinhua
Quality Operation
Excellence
Godfrey DAYO
Production Quality
CHEN Xiaoming
© 2015 General Electric Company - All rights reserved
Sales
BAI Xixin
Tendering
ZHANG Dayong
Supply Chain
LI Chenghai
Manufacturing
WANG Quguang
Lean & EHS
PEI Hanhua
General Service
JIN Zhicheng
11
STEAM POWER SYSTEMS | FROM GE
WBC Product Portfolio
Boiler Type
Range
Two
Pass
1,350 MW *
100 MW
 Bituminous
Sub-bituminous
 Lignite
(moisture <40%)
Coal-Fired
Oil-Fired
 Oil & Gas
* Oil-fired : up to 1,000 MW
100 MW
Tower
1,350 MW *
 Bituminous
Sub-bituminous
 Lignite
(all moisture level)
Hard Coal-Fired
CFB
Fuel Type
Lignite-Fired
* Lignite Tower: up to 1,100 MW
100 MW
660 MW *
 Full range of fuels
* Up to 660MW for lignite, higher for hard coal
HRSG
Drum
All sizes of GE gas turbines
Mills
HP Mill up to HP1303
SM Mill up to SM 31
BW Mill up to dia. 4400mm
© 2015 General Electric Company - All rights reserved
 Full range of fuels
for PC Boilers
STEAM POWER SYSTEMS | FROM GE
Manufacturing Capability
Capability
 WBC designs, manufactures and services subcritical, supercritical, ultra-supercritical and AUSC steam boilers.
 Chinese Market: Boiler Proper,
Overseas Market: Boiler Proper or Boiler Island.
 Certificates:

ISO 9001

EHS certificates

ASME “U” and “S” stamps

EN ISO 3834-2 (by TUV)

EN-PED

Class A Chinese license for boilers

EN 1090 Structural Steel Design
WBC business covers full length of utility
projects, from project development to project
hand over to commercial operation, with a
state of the art product manufacturing site.
© 2015 General Electric Company - All rights reserved
STEAM POWER SYSTEMS | FROM GE
GE Wuhan Boiler References
Strong experience both
domestically and globally for all
boiler products
Germany
Mannheim 9
1x910 MW
285 Bar
600 ºC / 610ºC
Netherland
Eemshaven
2 x 820 MW
299 Bar
600 ºC / 610ºC
US
PeeDee 1
1x640 MW
248 Bar
568 ºC / 596ºC
Poland
Opole
2x900 MW
263 Bar
603 ºC /
611ºC
Pakistan
Hubco
2 x 660 MW
254 Bar
568ºC / 571ºC
China
Turkey
Karabiga
2 x 660 MW
294 Bar
603ºC / 612ºC
Slovenia
Sostanj
1x600MW
291 Bar
600 ºC / 610ºC
Mexico
Altamira
2 x 165MW
131 Bar
540 ºC / 540ºC
Taian
2 x 350 MW
Binzhou Beihai
4 x 350 MW
Jinchang
2 x 330 MW
Hefeng
2 x 300 MW
Huangshi
1 x 300 MW
Chiping
2 x 300 MW
Huizhou
2 x 330 MW
Lanzhou
2 x 330 MW
Liaoyuan
2 x 330 MW
Luoyuan(USC)
2 x 660 MW
Tangshan
2x58 MW
Leiyang
1x300 MW
Mailiao(TW, USC) 2x600 MW
Estonia
Narva CFB
1x300 MW
174 Bar
541 ºC / 541ºC
Saudi Arabia
Yanbu
5 x 630 MW
258 Bar
542ºC / 540ºC
Projects under execution
ABC Orders from Thermal Service
ABC Main contracts by WBC
100% mfg OTD and no any
LD claimed by customers
Israel
Ashalim
1 x 121 MW
170 Bar
585ºC
Thailand
Mae Moh
1x600 MW
285 Bar
605 ºC / 611ºC
UAE/Dubai
Hassyan
4 x 660 MW
289 Bar
603 ºC / 612ºC
© 2015 General Electric Company - All rights reserved
Malaysia
Manjung
1x1000 MW
278 Bar
602 ºC / 603ºC
Pakistan
Thar II
2 x 330 MW
175 Bar
541 ºC / 541ºC
Vietnam
Thanglong
2 x 300 MW
174 Bar
541 ºC / 541ºC
Malaysia
Tanjung Bin
1 x 1000 MW
278 Bar
602 ºC / 603ºC
STEAM POWER SYSTEMS | FROM GE
New WBC- Main Product Manufactured
(after 2007)
Delivery
2017-2021
2016-2018
2017-2018
2015-2017
2016
2015-2016
2015-2016
2015-2016
2014/2015
2014/2015
2014/2015
2013-2014
2013/15
2012/13
2012/13
2011/12
2011/12
2010/11
2010/11
2011/12
2009/11
2008/09
2008/09
2008/09
2007/08
Plant
Hassyan
Thar II
Hubco
Thanglong
Mae Moh
Luoyuan
Karabiga
Ashalim
Tai’an
Altamira
Opole
Binzhoubeihai
Yanbu 3
Narva
TanjungBin 4
Manjung 4
Sostanj 6
Mannheim 9
Eemshaven A&B
Jinchang
Hefeng
Huangshi
Chiping
Huizhou
Liaoyuan
Customer
DEWA(UAE)/HEI
ENGRO(Pakistan)/CMEC
TEEG-ZEPC(Pakistan)
TLP (Vietnam)
EGAT (Thailand)
Huaneng (China)
CENAL (Turkey)
Megalim (Israel)
Guodian (China)
Isolux(Mexico)
ABD (Poland)
Weiqiao
SWCC (Saudi Arabia)
Eesti Energia AS (Estonia)
Malakoff (Malaysia)
TENAGA (Malaysia)
TERMOELEK (Slovenia)
GKM (Germany)
RWE Power AG (Netherland)
GEPIC (China)
State Grid (China)
Huadian (China)
Xinfa Group(China)
Guohua Power(China)
Datang (China)
Output, MW
Cycle, MPa/C/C
4x660
2x330
2x660
2 x 300
1 x 600
2 x 600
2 x 660
1 x121
2 x 350
2 x 165
2 x 900
4 x 300
5 x 630
1 x 300
1 x 1000
1 x 1000
1 x 600
1 x 910
2 x 920
2 x 330
2 x 300
1 X 300
2 x 300
2 x 330
2 x 330
28.9/603/612
17.5/541/541
25.4/568/571
17.4/541/541
28.5/605.6/611.6
29.3/605/623
28.36/603/612
17/585/NA
25.4/571/569
13.1/540/540
31.9/603/611
17.5/540/541
25.8/542/540
17.5/540/540
27.8/602/603
27.8/602/603
29.1/600/610
28.5/600/610
29.9/600/610
17.5/540/540
18.4/541/540
17.5/540/540
17.5/540/540
17.5/541/540
18.4/543/542
© 2015 General Electric Company - All rights reserved
Type
2-pass, USC
CFB, Sub
2-pass, SC
CFB, Sub
2-pass, USC
Tower, USC
2-pass, USC
CSR
2-pass, SC
CFB, Sub
Tower, USC
2-pass, Sub
2-pass, SC
CFB, Sub
2-pass, USC
2-pass, USC
Tower, USC
Tower, USC
Tower, USC
2-pass, Sub
2-pass, Sub
2-pass, Sub
2-pass, Sub
2-pass, Sub
2-pass, Sub
STEAM POWER SYSTEMS | FROM GE
New WBC- Main Product Manufactured
(after 2007) – Thermal Service
Delivery
2008 /10
2007/08
2013
2014
2015-2016
Plant
Lanzhou 2
PeeDee 1
Tangshan Banpu
Leiyang
Mailiao
Customer
GEPIC (China)
SANTEE COOPER (US)
Banpu(Thailand)
Datang(China)
FORMOSA(Taiwan)
Output, MW
2 x 330
1 x 640
2 x 58
1 x 300
2 x 600
© 2015 General Electric Company - All rights reserved
Cycle, MPa/C/C
Type
17.5/540/540
2-pass, Sub
24.8/568/596
2-pass, SC
9.8/540
2-pass(retrofit)
17.2/540/540 2-pass, Sub(retrofit)
25.8/538/569 2-pass, USC(retrofit)
16
通用电气武锅先进的技术
GE Wuhan Boiler Advanced
Technology
STEAM POWER SYSTEMS | FROM GE
Straight Flow Manufacturing process
跨1: 再热器/过热器Bay 1: Reheater/Superheater
气瓶仓库 Gas bottle storage
危险品仓库 Hazardous waste storage
跨2: 省煤器/散管Bay 2:Economizer/Loose tube
跨3: 膜式壁 Bay 3: Panel workshop
跨4: 集箱 Bay 4: Header
跨5: 汽包 Bay 5: Drum
原材料货场 Raw material storage
机加车间 Machine shop
汽包射线探伤 X-ray bunker for drum
热处理炉Heating furnaces
喷丸 Shot blasting
变电站
Substation
油漆间 Painting cabin
生产办公楼
Mfg. offices
材料研究所
Material Lab
主办公楼
Office building
单流向工厂，制造世界一流的锅炉产品
Single-flow factory to deliver world-class boilers
© 2015 General Electric Company - All rights reserved
STEAM POWER SYSTEMS | FROM GE
Straight Flow Manufacturing process
456 m
Bay 4: Headers
跨四：集箱 21,600 m2
Bay 3: Panels
跨三：膜式壁 21,600 m2
36 m
Bay 2: Economizers, Loose Tubes, Burners
跨二：省煤器、散管及燃烧器 21,600 m2
Bay 1: Superheater/Reheater heat
exchangers
跨一：过热器、再热器 21600 m2
北N
600 m
© 2015 General Electric Company - All rights reserved
完工产品 Finished Goods
原材料 Raw Material
Bay 5: Drums
跨五：汽包 16,400 m2
STEAM POWER SYSTEMS | FROM GE
WBC Lab Capability
 National accredited Laboratory
certified to ISO/IEC 17025:2005, the
first lab in domestic boiler industry.
 An accredited lab of Hubei Entry-Exit
Inspection and quarantine Bureau.
Technical Cooperation
 ASME Volume Ⅱ Chinese working group to promote
Chinese material drawn into ASME code.
 China Special Equipment Inspection and Research
Institute to conduct failure analysis;
 well-known universities and colleges to conduct
material R&D;
 Steel mills to conduct new material property
evaluation and new material localization;
Future Cooperation with Thermal Service
o Material Test
o Failure Analysis
o Remaining Life Evaluation
o Condition Assessment
o Site test /witness
o technical problem solving
© 2015 General Electric Company - All rights reserved
20
STEAM POWER SYSTEMS | FROM GE
Process Automation & Integration
Significant automation is ensuring repeatable quality standards for:
• Straight tube cut and prep (automated measure, cut, prep and marking)
• TIG/MAG straight tube and orbital welding
• System bender for elements
• Single tube bender for burner panels
• All supported by iGEMS
Straight tube prep
Automated Tube Cut and
Preparation line
Pretreatment of the tubes
before welding. 20K welds
output per month
Input drawing, cutting,
beveling and polishing per
designated length
TIG/MAG
Tube to tube connect
welded automatically
Can weld any material for
boiler. 10K butt welds
output per month
High quality: Reject rate
lower than 0.5%
System bender
4 sets of bending device
and 1 set of heating device
Controlled by CNC
automatically, 30k bends
output per month
Most advanced benders in
the world
© 2015 General Electric Company - All rights reserved
Single tube bender
Designated data link to the
bender directly,
3D auto CNC controlled.
More than 300 different
kinds of 3D single tube can
be combined together
perfectly
STEAM POWER SYSTEMS | FROM GE
Welding Technology
• Welding is the most critical and essential process in boiler making
• Wuhan’s reference covering all low to high grade/new materials and major
international Codes applied in global utility boiler industry
• More than 491,284 shop welds by new WBC have been in service and there is
zero failure due to defective welds.
• Complete development, training, analysis and technical support capability.
• Significant level of automation and machine controlled welding processes.
Welding Training
In house welder training
Centre & welder certification
covering all Code requirements
Welding Automation
Straight tube welding
Orbital welding
Nipple welding
Welding Technology
In-house laboratory,
welding development
for all material and
codes
© 2015 General Electric Company - All rights reserved
Welding Quality
Reject rate <2%
Zero weld shop
leakage on site
STEAM POWER SYSTEMS | FROM GE
Straight-Tube-Welding First Pass Yield (FPY)
100.00%
99.50%
99.50%
Straight tube welding Yield
99.00%
98.50%
98.00%
97.50%
97.00%
96.50%
96.00%
95.50%
95.00%
20
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• Average FPY in the last 14 months is 99.95%.
• Sigma value is 4.8
• Process capability (CPk) is 1.6
© 2015 General Electric Company - All rights reserved
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STEAM POWER SYSTEMS | FROM GE
GE WBC NDT Requirement of ASME Boiler Pressure Parts
Rev.00 Apr. 7th, 2017
Method and Extent of Non-destructive Testing
P-No. of Materials
Typical Material
Specification/Grade
Outside Diam.
(mm)
OD≤100
100 ＜OD≤114.3
1
SA-105/106/210
OD>114.3
OD≤100
4
SA-213 T11/T12
SA-335 P12
SA-234 WP11/12
100 ＜OD≤114.3
OD>114.3
OD≤100
5A
SA-213 T22
SA-335 P22
SA-234 WP22
100 ＜OD≤114.3
OD>114.3
OD≤100
8
SA-213
TP304/310S/321/347
SA-213 TP316
100 ＜OD≤114.3
OD>114.3
OD≤100
15E
SA-234 WP91
SA-213 T91/92
SA-335 P91/92
SA-336 F91
100 ＜OD≤114.3
OD>114.3
Wall Thickness
(mm)
Before PWHT
After PWHT
Butt
Nozzle
Fillet
Butt
Nozzle
Fillet
T≤13
DR/RT 10%
NA
NA
NA
MT 100%
MT/PT 10%
13 ＜T≤19
RT 100%
NA
NA
NA
MT 100%
MT/PT 10%
T>19
RT 100%
NA
NA
NA
MT 100%
MT/PT 10%
13 ＜T≤19
NA
NA
NA
RT 100%
MT 100%
MT/PT 10%
T>19
NA
NA
NA
PAUT/RT 100%
MT 100% and
UT 100%②
MT/PT 10%
T≤13
DR/RT 10%
NA
NA
NA
MT 100%
MT/PT 10%
13 ＜T≤19
RT 100%
NA
NA
NA
MT 100%
MT/PT 10%
T>19
RT 100%
NA
NA
NA
MT 100%
MT/PT 10%
13 ＜T≤19
NA
NA
NA
RT 100%
MT 100%
MT/PT 10%
MT/PT 10%
T>19
NA
NA
NA
PAUT/RT 100%
MT 100% and
UT 100%②
T≤13
DR/RT 10%
NA
NA
NA
MT 100%
MT/PT 10%
13 ＜T≤19
RT 100%
NA
NA
NA
MT 100%
MT/PT 10%
T>19
RT 100%
NA
NA
NA
MT 100%
MT/PT 10%
13 ＜T≤19
NA
NA
NA
RT 100%
MT 100%
MT/PT 10%
MT/PT 10%
T>19
NA
NA
NA
PAUT/RT 100%
MT 100% and
UT 100%②
T≤13
DR/RT 10%
NA
NA
NA
NA
PT 10%
13 ＜T≤19
RT 100%
NA
NA
NA
NA
PT 10%
T>19
RT 100%
NA
NA
NA
NA
PT 10%
13 ＜T≤19
RT 100%
NA
PT 10%
NA
NA
NA
T>19
PAUT/RT 100%
PT 10%
PT 10%
NA
NA
NA
T≤13
DR 100%①
NA
MT/PT 10%
MT/PT 10%
MT 100%
MT/PT 10%
13 ＜T≤19
RT 100%
NA
MT/PT 10%
MT/PT 10%
MT 100%
MT/PT 10%
T>19
RT 100%
NA
MT/PT 10%
UT 100%
MT 100%
MT/PT 10%
13 ＜T≤19
RT 100%
NA
MT/PT 10%
UT 100%
MT 100%
MT/PT 10%
UT 100%
MT 100% and
UT 100%②
MT/PT 10%
T>19
PAUT/RT 100%
UT 100%
MT/PT 10%
-
Super304H
OD≤89
T≤13
DR 25%①
NA
NA
NA
NA
PT 5%
Dissimilar Metal Welds
Ferritic-Austenitic
OD≤89
All
DR/RT 100%
NA
PT 10%
PT 5%
NA
NA
General Notes:
Notes:
1:These NDT requirements are in compliance with ASME Code Section I, B31.1 and GE Global Standard 28-94.
2:RT = Radiographic Testing(film); DR = Digital Radiographic Testing; UT = Ultrasonic Testing; PAUT = Phased Array Ultrasonic Testing; MT = Magnetic particle Testing; PT = Penetrant Testing;
3:For the not 100% proportion of testing, random spot check for butt weld by each welder, random spot check for nozzle weld and fillet weld by the weld number.
①:RT will be completed in lieu of DR when the DR cannot be completed due to product configurations.
②:The Nozzle OD greater than 114.3mm, and the weld was full penetration fillet weld, UT will be performed.
© 2015 General Electric Company - All rights reserved
STEAM POWER SYSTEMS | FROM GE
Digital RT & QC
Digital RT & Quality Control:
• It is accepted by all governance Codes and customers (the
only one in China boiler industry accepted by EN authority)
• GE shops and WBC have the highest use of advanced
DIGITAL REAL TIME RT equipment in the boiler industry
• Compared to film radiography, productivity increased by
700% and a cycle time reduced by 600%
Digital Radiography in accordance with ISO 17636 - 2 “Nondestructive testing of welds – Radiographic testing – Part 2:
X- and gamma-ray techniques with digital detectors. TUV
Sud, TUV Rhineland & UDT (Poland) certified.
© 2015 General Electric Company - All rights reserved
STEAM POWER SYSTEMS | FROM GE
Stainless Steel Tube ID Shot Peening
Shot Peening:
Thinner Oxidation
Layer
 Clean up oxidation layer of steel tube inner surface
 Increased corrosion resistance, fatigue resistance
and surface hardness of material
 Produce a compressive residual stress layer and
modify mechanical properties of metals
Un-peened 304H vs Peened at 600°C for 3000 hours
No Visible
Oxidation Layer
 Prolonged material & product life time
 Shot-peened S304H can replace material of higher
level and higher price, or perform much longer life
time than the un-peened material.
Un-peened 304H vs Peened at 650°C for 10,000 hours
•
WBC was the first boilermaker in the world to have in
house Shot Peening capability for supercritical boilers.
•
Our shot peening process and machines were codeveloped with strategic supplier for our product.
•
•
Capability: max 15m (max 10m the other suppliers)
Material: Stainless steel incl. Super304H
© 2015 General Electric Company - All rights reserved
STEAM POWER SYSTEMS | FROM GE
Continuous Manufacturing R&D
•
•
•
•
Robotics and advanced welding processes
New material development
Induction heating for water-wall panels
Digital data collection and management
Manufacturing of New Boiler Materials
Summary of Total Work Scope
T23
T24*
T/P91
T/P92
NO6617
Validation requirements
Alstom standardised Specification /
DRAFTED VALIDATED DRAFTED VALIDATED DRAFTED VALIDATED DRAFTED VALIDATED DRAFTED VALIDATED
T/P91 & T/P92
NO6617
Procedures
Base Metal Specifications
T24
TASK
FORCE
FY14
FY14-17
FY10
FY11
FY12
FY13-17
FY14
FY15
Filler Metal Purchase Specs.
SMAW
FY14
FY14-16
N/A
N/A
FY11
FY14-16
FY12
FY14-16
NA
NA
PQR
PQR+ Creep NA
GTAW
FY14
FY14-16
FY13
FY13
FY11
FY12-15
FY14
FY14-16
FY14
FY15
PQR+SCC
PQR
PQR
SAW
FY14
FY14-16
FY11
FY11
FY11
FY12-15
FY14
FY14-16
NA
NA
PQR+ hardness
PQR
NA
FCAW
N/A
N/A
N/A
N/A
FY12
FY12-15
FY12
FY14-16
NA
NA
PQR
NA
Welding/ Heat Treatments
Preheat/Interpass
FY15
FY14-16
FY13
FY13
FY11
FY11
FY13
FY13-15
FY14
FY15
Covered by testing Covered by
Covered by
Hydrogen Bake
N/A
N/A
N/A
N/A
FY11
FY11
FY13
FY13-15
NA
NA
above
testing above testing above
Subcritical PWHT < A1
FY15
FY15
FY13
FY13
FY11
FY12-13
FY14
FY14-15
NA
NA
Normalize & Temper
FY15
FY14-16
N/A
N/A
FY11
FY14-15
FY12
FY14-15
NA
NA
PQR+ Creep
PQR+ Creep NA
Bending & Forming
Cold Strain Limits
FY11
FY14-16
N/A
N/A
FY11
FY15-16
FY11
FY14-16
FY14
FY15
Creep
Creep
Creep
Subcritical PBHT
FY11
FY14-16
N/A
N/A
FY11
FY15-16
FY11
FY14-16
NA
NA
Creep
Creep
NA
Normalize & Temper
FY11
FY14-16
N/A
N/A
FY11
FY15-16
FY11
FY14-16
NA
NA
Creep
Creep
NA
DMW Study
Inventory of various Alstom practice
FY14
NA
NA
NA
Recent Failures and Path Forward
FY11
NA
Creep
© 2015 General Electric Company - All rights reserved
通用电气武锅先进的管理
GE Wuhan Boiler Advanced
Management
STEAM POWER SYSTEMS | FROM GE
Boilers Manufacturing-Operational Excellence
OPERATIONAL EXCELLENCE
NCR detection &
prevention
8D with focus on
top systemic quality
issues
GMQS: Global
Manufacturing
Quality System
Lead Time Reduction
Cost Reduction for
Major Products
Site deliveries
modularized
Increase awareness
and actions
For Plants/Boilers
TMSys Lean
Manufacturing
Boiler
Modularization and
Erection Strategy
AZDP GE Zero
Deviation Plan
Manufacturing R&D
Knowledge Transfer
iGEMS
Brick Boiler Design
5S
Design for
Manufacturing
Product Platform
Development
Develop / train EHS
Community
© 2015 General Electric Company - All rights reserved
STEAM POWER SYSTEMS | FROM GE
Digital Industry-iGEMS Process
Create AutoCAD 3D model
ENGINEERING
Fabricate and assembly
according to iGEMS reports
MANUFACTRUING
Export to iGEMS to generate
iGEMS model
ENGINEERING
Give design parameters such
as bending, scarfing etc.
ENGINEERING
BOM for procument
ENGINEERING
Workshop can simulate the
manufacturing process
MANUFACTRUING
Release the relevant reports’
which generated by iGEMS
automatically, to workshop
MMI
Edit traveller & WC report,
assign shop hours
MMI
An internally developed robust CAD CAM process that starts in the initial design phase and carries through to the
manufacturing work centers.
© 2015 General Electric Company - All rights reserved
STEAM POWER SYSTEMS | FROM GE
Quality Management System - GMQS
GMQS - Global Manufacturing Quality System
FMEA
Mistake-Proofing
MSA
SPC
Cpk, Cmk
NCR
CoPQ
Customer
Commitment
Audits
Manufacturing
Nonconformance
Management
Manufacturing
Process
Development
Manufacturing
Process
Monitoring

Target
Manufacturing quality system standardization
Manufacturing process capability stable promotion
Product quality continuous monitoring
Market competitiveness keeping robust
Ensure Customer Satisfaction by building manufacturing capability focusing on QA rather than QC
© 2015 General Electric Company - All rights reserved
STEAM POWER SYSTEMS | FROM GE
Quality Management System – GE One Boiler Supplier Management
Boiler Supplier Qualification Approval Committee (Boiler Level Engineer, Quality, Supply Chain)
Centre Transition Core Teams
Wuhan
Windsor
Stuttgart
-2 Pass
-CFB
-Tower
-2 Pass
-CFB
-Tower
Delhi
-2 Pass
-CFB
Supplier Commercial
Evaluation
• NDA
• SPIQ
• SCC
Supplier QEHS
Qualification
• ISO system
• Quality system
• EHS
Supplier Product
Qualification
• Conformity with GE technical requirements
• Key process
GB
Code
CSR
FEF
SGDC
ASME
Code
Key Commodities to be approved by SQAC
• Target setting
• Global Sourcing Strategy
• Review Key Commodity SQA
• Validation of action plans
SCM Director
SCE Result
QEHS Report
EN
Code
SQA
Supplier
Qualification
Approval
QPI Director
SQA
PQ Report
Engineering Director
IBR
Code
Key User maintain PowerSource Database
Global Supplier Management Database PowerSource
© 2015 General Electric Company - All rights reserved
STEAM POWER SYSTEMS | FROM GE
Integrated Advanced Technology, Design and Manufacturing
Original
Technology
TECHNOLGY CENTERS
 Windsor, GE in USA: Two-pass Boilers
 Stuttgart, GE in Germany: Tower Boilers
 Massy, GE in France: CFB Boilers
Massy
Windsor
Stuttgart
Wuhan
India
Knowledge Transfer: Provider and Receiver
One Process
Centre Actions
Centre Actions
Centre Actions
© 2015 General Electric Company - All rights reserved
Centre Actions
Intelligent
Manufacturing
Standard WBS / Division of Work
Centre Actions
International
Design
One Boiler
Resource Planning and Manufacturing Coordination
STEAM POWER SYSTEMS | FROM GE
Factories Load Chart – Wuhan
By Quarter
© 2015 General Electric Company - All rights reserved