Excellent
Engineering
Solutions
Health & Safety
Employee health and safety is of paramount importance to The Weir
Group. The Group is committed to zero accident workplaces.
To ensure this we have introduced the Weir Environment, Health and
Safety (EHS) System. The Weir EHS system sets out global standards for
areas including behavioural safety, operational control of risk, fire and
environment.
The Group’s policy is that all its operations aim to achieve OHSAS 18001
(Occupational Health and Safety Assessment Series) accreditation.
Find out more about The Weir Group at www.weir.co.uk
Introduction to
The Weir Group
Weir is a FTSE100 global engineering solutions provider focused on the
minerals, oil and gas and power markets.
The Group designs, manufactures and provides aftermarket support and
services for pump and flow control products, with market leadership
positions in a number of product areas.
Weir Engineering Services
Oil & gas production.
Refining.
Waste-to-Energy. Industrial process.
Weir’s services are applicable to a diverse base of power, industrial and oil & gas facilities such as:
Nuclear power stations Thermal power stations Hydro power stations Geothermal power stations
Waste-to-energy and biomass power stations Wind farms
Oil & gas production facilities Refineries and petrochemical plants General industrial plants
Water treatment and pumping stations The Weir service portfolio includes:
Pump services
Valve & Actuator services Turbomachinery services Advanced Part Solutions Specialist Coatings services Hydro-Electric Power services Wind Power services Plant Rehabilitation services Allen Steam Turbines™
Nuclear power. Wind power.
Hydro power.
Sitting within the Power & Industrial division of The Weir Group, Weir Engineering Services
provides a wide range of services aimed at optimising the long term operating environment
of plants and facilities, bringing increased performance efficiencies and lower lifetime costs.
OUR OFFER
Complete maintenance programs covering standard service to refurbishment with repairs including welding and re-machining
Full range of testing capabilities to identify performance and condition issues (including noise, vibration and thermometric efficiency)
Advanced Part Solutions providing re-engineered and manufactured parts including performance and material upgrades
Specialist coatings to protect against corrosion, erosion and cavitation and to enhance fluid flow Services for mechanical seals from refurbishment, upgrades and managed service exchange to supply of new seals
Complete service for the manufacture, repair and overhaul of submersible wet wound pumpsets and electric motors
Supply of the complete range of Roto-Jet® high
pressure pitot tube pumps as well as spares Spare parts supply from stock
Pump Services
Weir is synonymous with world-leading pumps and our vast OEM knowledge and engineering
skills enable us to provide a complete service for the repair, overhaul and upgrade of both
Weir and non-Weir pumps. These services are delivered on-site and in specialised workshops
and cover a comprehensive application range.
Product coverage:
All legacy Weir branded pumps and current brands
Pumps from any manufacturer covering typical applications such as: feedwater, booster, boiler circulating, condensate extraction, cooling water, fuel/ lube oil, drain, seawater lift
Pump categories: horizontal and vertical split case, submersible and vertical split case, submersible and immersible, axial and mixed flow, multistage
Contact details:
Workshop pump overhaul. Winding of a 1000kW submersible motor. Roto-Jet® pump supply and service.
YOUR BENEFIT
Lower total cost of ownership through increased mean time between failure and reduced unscheduled maintenance
Full knowledge of issues and options to inform decision making for best case resolution Return to existing state or improved state based
on repair or upgrade work to your specification Optimised pump performance to meet process conditions and extended lifespan of equipment Reduced power costs with maximised pump
efficiency and extended life of internal parts Improved equipment reliability with repairs and
upgrades meeting changed process conditions and HSE requirements
Cost savings when avoiding replacement with new Long term pump reliability from high quality
manufacture and pre-supply performance testing Return to service with extended lifespan and
improved performance through repair and engineered upgrades and re-rates
Reliable and efficient pumps
OEM spare parts and service support Maximised uptime due to fast response
Split case pump under test.
As a leading OEM valve supplier across multiple industries, Weir is well positioned to
support valves and actuators throughout their operational life. This is delivered through
a comprehensive portfolio of maintenance services and specialised engineering solutions
enabling effective management of your assets.
Valve & Actuator Services
OUR OFFER
Outage and shutdown project management and delivery across all valves and controls. Delivered by experienced managers and onsite engineers and backed up by fully equipped workshops
Statutory inspections, overhauls and repair of valves and actuators of any manufacturer (including asset management and maintenance planning)
In-situ valve seat replacement combining Weir service expertise with leading welding technology
Online safety valve testing and analysis (hot and cold/ fast and safe)
Operation and service training programs carried out by our valve and controls experts
Maintenance programs and OEM parts, upgrade kits and replacements for Hopkinsons®/ Autotork™
actuators
Specialist Control Valve Services with state-of-the-art testing equipment, software and experienced technicians backed by OEM technical expertise
Full HSEQ process control. In-situ welding machine in operation.
Dedicated actuator workshop. YOUR BENEFIT
Controlled delivery from a single source with effective pre-planning and project management Prompt on-time return to service with full HSEQ
process compliance throughout
Reliable ongoing operation with leak-free valves serviced by experts in valve design and operation Optimised operation of all valves and controls with
security of work carried out to certified levels by proven reliable company
Ease of management through consolidation of service and maintenance programs under Weir Minimised operational downtime with seat issues
resolved without valve removal
Cost effective solution avoiding new valve replacement and extending valve lifespan Maximised valve integrity and efficiency avoiding
interruption of production
Control over standard maintenance activities with personnel trained to Weir’s standard
Extended lifespan of reliable actuators without costly and time intensive change-outs
Reassurance of safe and compliant valves with full test certification
Any faults or issues identified along with best resolution options to maximise valve integrity and efficiency from valves returned to service
Contact details:
Product coverage:
Butterfly, gate, globe, check, safety and control valves from Weir or any manufacturer along with associated actuators
Simultaneous testing of valve, actuator and controls on specialist equipment.
Turbomachinery Services
Weir’s knowledge of steam turbines and gas compressors is founded on a combination of
manufacturing heritage and long-standing service provision. Weir applies this experience
to deliver a range of services from inspection and repair through to complex refurbishment
projects; all designed to minimise operational cost, extend product life and increase efficiency.
Product coverage:
Gas compressors: all axial, centrifugal and reciprocating models from any manufacturer Steam turbines: all models under 100MW or above if required through alliance partners
Supplementary products such as gearboxes, power recovery turbines, blowers, fans and general ancillary equipment
OUR OFFER
Inspection and repair services covering compressors, turbines and auxiliary equipment as stand alone project or part of outage
Managed refurbishment and enhancement of turbomachinery
upgrades and re/de-rates in response to changes in operating conditions
product enhancements designed and manufactured to address operational issues Advanced Part Solutions providing re-engineered and manufactured parts including performance and material upgrades
Full range of performance tests to deliver best case solutions incorporating:
diagnostic analysis and condition assessments noise and vibration analysis
conceptual design and performance mapping Specialist coatings to counter corrosion, erosion and cavitation
All services delivered using a combination of local capability, field engineers and centre of expertise workshops
YOUR BENEFIT
Reduced management with Weir as single source provider of all service and repairs
Optimised turbine or compressor performance with updated designs to meet current and future process conditions
Greater return on investment from existing machines with extension of operable life Minimised downtime through well planned
project delivery
Extended lifespan of equipment through enhanced material durability
Increased performance through components re-engineered to latest standards
Alternatives to direct repair or replacement Reduced downtime by identification of issues prior
to full shutdown followed by targeted action Full knowledge of issues and options to inform
decision making for best case resolution Return to existing state or improved state based
on repair or upgrade work to your specification Extended lifespan of equipment and components
through enhanced material engineered coatings Minimised downtime and cost with work carried
out by best-fit engineers at facilities relevant to your job or project
Contact details: [email protected] Workshop assembly of compressor. Rebladed turbine. Installation of overhauled steam turbine.
Completed rotor and bundle for gas platform.
Advanced Part Solutions
Weir has over 20 years experience in the re-engineering and manufacture of component parts
and assemblies, ranging from simple machined sleeves through to complete re-engineered
machines. Weir’s Advanced Part Solutions provides re-engineered and manufactured parts
including performance and material upgrades.
Product coverage:
Pumps from any manufacturer covering typical applications such as: feedwater, booster, boiler circulating, condensate extraction, cooling water, fuel/ lube oil, drain, seawater lift
Valves: butterfly, gate, globe, check, safety and control Gas compressors: all axial, centrifugal and reciprocating
models from any manufacturer
Steam turbines: all models under 100MW from any manufacturer
Other rotational plant such as mixer arms and blades, fans and blowers
Shipping and derrick repairs, casting moulds, damaged special gears and systems
Manufacturing process equipment
OUR OFFER
Weir is able to provide a timely, cost-effective solution when you are faced with potentially long delivery times, high cost or dated OEM options. In some cases the OEM may no longer supply or exist Using the latest technology Weir can obtain an accurate profile of equipment regardless of complexity. Combined with an in-depth understanding of operating conditions and your requirements our design experts can engineer the optimal design in the most appropriate material Newly designed components and equipment benefit from modern manufacturing processes to ensure quality and cost effectiveness. All new parts carry a Weir warranty
Management of your entire engineered spares supply requirements. From on-site data collection to on time supply for stock replenishment
All Weir work is carried out within a robust reverse engineering policy
Full range of service and maintenance options available with current design documentation to support
YOUR BENEFIT
Alternatives to direct repair or replacement Latest materials and techniques used for design
and manufacture
Quick return to service with short lead times Optimised equipment performance to meet current
and future process conditions through components re-engineered to the latest standards
Extended lifespan of equipment through enhanced material durability
Reliable and durable solutions fit for purpose Reassurance of dealing with a major manufacturer Reduced management effort with single source
supplier
On time delivery with unique part code assigning for ease of re-order
Reassurance of quality controls throughout that are designed to respect third-party intellectual property rights
Operational confidence
Control over any future component design changes
Contact details:
Re-engineered compressor impeller.
Precision scanning to build 3D model.
Quality component manufacture.
1500mm dia. inner bowl from main cooling water pump.
Global Capability
With a global footprint, Weir has a far reaching capability. A selection of projects across the
world is given below. For more information please visit www.weirpowerindustrial.com and
for details of what engineering services Weir can offer in your territory, please contact us at
[email protected]
Coal & Nuclear Power Plants, UK
Full valve outage management and service delivery.Waste-to-Energy Plant, Netherlands
Supply and installation of Allen Steam Turbines™ turbo-generator package.Coal & Nuclear Power Plants, Canada
Overhaul and replacement of Hopkinsons®actuators across multiple sites.
Wind Farms, Brazil
Electrical and mechanical works and supply and installation of climb assistance equipment.
Off-Shore Platform, Trinidad & Tobago
Compressor overhaul, service support and commissioning of compressor train.Steel Plant, Libya
Rehabilitation of power unit (85MW turbine, generator, pumps and valves including re-engineered parts).
Coal-Fired Power Plant, South Africa
In-situ valve seat replacement program.Desalination Plant, Kuwait
Refurbishment and re-tubing of distillers and overhaul of pumps.
Gas Processing Plant, Iraq
Refurbishment of 4 compressor trains (including associated turbines and pumps).Gas Platform, Malaysia
Re-rating of 3 gas compressors (including material upgrades).
Geothermal Power Plant, Philippines
Refurbishment project covering pumps, valves, engines and generator.Specialist Coatings Services
Weir specialises in the application of high performance protective linings and coatings
using an extensive portfolio of techniques and products. Combined with our long standing
knowledge of operational environments across many industries, our coatings can be relied
upon to protect equipment surfaces and enhance systems.
Product coverage:
Pumps and rotating equipment Valves and associated control devices
Tanks, vessels, storage equipment, large and small bore pipework
Metal and concrete structures
OUR OFFER
Coatings designed to protect equipment, pipework, vessels and structures from the effects of erosion or corrosion caused by water or chemical substances Coatings designed to enhance the flow of fluids through equipment and pipework
Weir uses an extensive range of coating products which are carefully selected to best meet the usage requirements and environment
Our premium composite ceramic product can even be used to patch and reshape components to protect against extreme abrasion and chemical attack
Weir uses specialist SQEP* technicians and a variety of techniques to apply the coating to high standards in quality and process control
Services are delivered from dedicated facilities fully equipped for leading preparation and application techniques and through a team of specialised field service engineers. Projects managed to high standards throughout
YOUR BENEFIT
Reduced maintenance and repair costs by extending the time between failures caused by surface wear and corrosion
Increased performance of equipment and systems leading to cost saving in terms of the energy required to perform the required tasks
Assurance of most appropriate resin or powder coating product selected to meet specific needs by provider who understands products and systems Greater equipment and system resilience
resulting in lower maintenance costs and greater operational uptime
Assurance of high quality workmanship maximising lifespan of application
Delivered on time and on budget with minimised downtime due to experienced management and project team
Contact details:
Glass flake lined ECW pipework. Blast surface preparation. Spray coating application to valve.
Epoxy powder coating of split case pump.
Hydro-Electric Power Services
Weir offers a world class portfolio of skills in hydro equipment refurbishment developed
over more than 50 years. Combining our service experience with in-house design capability
from Weir American Hydro and alliance partners, Weir can deliver a comprehensive
maintenance, replacement and rehabilitation service.
Product coverage:
All main plant components and systems within small to large power stations
Runner replacements and upgrade for Francis and Kaplan turbine designs
OUR OFFER
Hydro station refurbishment and rehabilitation projects covering:
mechanical installation and overhaul
refurbishment and replacement of auxiliary systems generator overhaul
new protection and control equipment full project management to installation and
commissioning
Comprehensive maintenance service packages, covering all mechanical elements of the plant, from call-off contracts to framework agreements
Design and supply of high performance runners to upgrade existing systems (including full installation and commissioning service)
Specialist coatings for key plant components (including spiral casings and draft tubes, penstocks, valves, guide and stay vanes and tanks)
YOUR BENEFIT
Complete solution from a single source (Weir consortium) providing controlled delivery of project from end-to-end
Increased performance through upgrades to critical components and application of system knowledge
Increased asset lifespan and reduced requirement for major intervention
Reassurance of long term reliable performance and safety
Higher levels of uptime due to avoidance of unscheduled interventions and rapid response to emergency issues
Increased revenues through higher generating efficiencies from the same water resource through optimised design
Increased system performance due to enhanced flow through components
Longer component life spans through reduced corrosion and cavitation
Contact details:
Installation of 110” Francis runner.
Service engineers onsite. 127” Kaplan runner. Refurbished Pelton turbine.
Wind Power Services
Weir provides bespoke service and engineered solutions aimed at increasing performance
for wind turbine fleets and maximising uptime. Combined with Weir YES, our service offer
includes maintenance, refurbishment, management and commissioning of resources. Our
services are provided via central hubs using engineering experts and delivered through a
network of field engineers.
Product coverage:
Products from all major manufacturers: gearbox, rotor, drivetrain, yaw, generator, electrical systems
OUR OFFER
Operation and maintenance(including asset management) featuring routine performance monitoring and fault diagnosis
End of warranty engineering inspection service
Major component repair and refurbishment from removal to refit
Gearbox servicing options from standard
maintenance and repair to fully managed programs and refurbishment
Critical parts supply and installation (OEM parts or re-engineered where required)
Construction commissioning and turnkey contracts
YOUR BENEFIT
Reduced management complexity through single source service provision
Long term operational success with timely interventions and engineered solutions to technical issues
Impartial assessment enabling warranty to be fully utilised and reassurance of smooth transition into post-warranty life
Minimised downtime with rapid turnaround and quality assured workmanship
Performance enhancements from material upgrades
Reliable performance and issue avoidance through scheduled maintenance
Optimised performance and minimised downtime through bespoke service management and gearbox exchanges
Minimised downtime with rapid parts change-outs and return to service
Reduced management requirement with Weir handling the whole process
Lower cost and/or part life improvements through re-engineering
Controlled delivery with effective pre-planning and project management
Reliable performance through knowledgeable installation of multiple turbine types and vendors
Contact details:
Wind turbine installation services.
Onsite inspection and maintenance. Replacement gearbox preparation.
Gearbox during workshop overhaul.
Plant Rehabilitation Services
Weir’s plant rehabilitation services are aimed at increasing electrical and industrial power
plant performance and extending lifespan. Weir unites its own engineering capabilities with
industry leading experts in total system and major component design to ensure best-in-class
knowledge can be applied throughout.
Product coverage (with alliance partners):
Emission Control, Burners and Pipework Boiler Pressure Part Design and Manufacture Pipework System Design, Installation and
Refurbishment
Process Control and Instrumentation Pump and Motor Refurbishment Gas Compressor Refurbishment
Steam or Hydro Turbine/ Generator Refurbishment Valve and Actuator Refurbishment
OUR OFFER
Complete plant rehabilitation from initial baseline assessments through to supply, overhaul and commissioning
In-depth understanding of all issues specific to your plant with experts specialising in the design and operation of each piece of equipment and process Experienced system engineers to ensure each component of the plant integrates successfully in the system
Detailed planning and end-to-end support from project managers experienced across power plant maintenance and infrastructure projects
Project engineers and managers trained in delivering projects compliant with HSEQ process
All equipment and components supplied are manufactured to international standards
YOUR BENEFIT
Minimised management complexity and project risk by dealing with a single team from enquiry to completion
Cost effective delivery of whole project Generation capabilities increased and reliable
performance across whole plant through best-in-class refurbishment and/or selection of new equipment
Optimised solution from fuel input to electrical output meeting the required performance specification and budget
Increased revenues due to return to operation on time and budget minimising generation downtime Assurance of project delivery with clear view of
progress until handover to your operational team Minimised downtime or projects delayed due to
accidents
Designed with regulatory environmental compliance considerations
Reliable ongoing performance of installed or refurbished equipment
Contact details:
Propane train refurbishment in Middle East.
Initial inspection of coal-fired unit.
Work on desalination plant.
Refurbished turbine from steel complex.
Allen Steam Turbines
™
Through our Allen Steam Turbines
™
brand, Weir offers a proven range of turbine solutions
designed to meet the industrial challenges of today’s need for power, steam and heat.
Suitable for environments requiring back-pressure, condensing and/or steam extraction
capabilities, the range includes multi-stage and single-stage models up to 65MW.
Product coverage:
Full turbo-generator package incorporating gearbox, generator, condenser and complete control
and protection systems sourced from leading manufacturers and flexible to meet customer requirements
Power range up to 65MW; Inlet pressures up to 86 bar; Inlet temperatures up to 520˚C
OUR OFFER
Flexibility to meet the precise operating conditions for which the machine is intended within
standardised frame sizes
Custom engineered turbine, skid mounted and with the best generator options available; all sourced and managed using our extensive expertise
Weir takes you through the design stages, supporting with application specific advice and keeping your team up-to-date with everything needed to deliver your project successfully Weir engineers are an integral part of your project team; with training of your plant maintenance and operational personnel as required
Technically well designed and manufactured product through the modern production capability of our manufacturing partner, NG Metalúrgica
Full range of service and maintenance packages to ensure long-term reliability and problem resolution
YOUR BENEFIT
Cost effective solutions maximising efficiency of each application
Flexible package solution tailored to your needs Single responsible source to deal with
Ease of delivery, installation and commissioning on site
Assistance given at all stages of the contract Project delivered, commissioned and handed over
within schedule
Smooth transition into operational life and in-house team able to take over control Provision of proven, reliable machine
benefiting from latest technological and design enhancements
High efficiency within the power ranges and applications served
Operational confidence from beginning and beyond
Assurance of continual service Maximises operational life
Contact details:
Turbine package installed in waste-to-energy plant. Multi-stage turbine in production.
Turbine with controlled extraction in sugar mill.
30MW multi-stage turbine.
Excellent
Engineering
Solutions
Please contact us for further details:Weir Engineering Services Pegasus House Bramah Avenue East Kilbride G75 0RD, UK Tel: +44 (0)141 308 2800 Email: [email protected] Web: www.weirpowerindustrial.com
Copyright © 2013 Weir Engineering Services Ltd. All rights reserved. HOPKINSONS and AUTOTORK are trademarks and/or registered trademarks of Weir Valves & Controls UK Ltd; ALLEN STEAM TURBINES is a trademark of Weir Engineering Services Ltd; ROTO-JET is a trademark and/or registered trademark of Envirotech
