Ansaldo Energia: Discover our energy — Transcript

Full transcript

1. 0:00[music]
2. 0:08Energy transition is the challenge of
3. 0:10our time. The goal is to meet growing
4. 0:13energy demand and ensuring reliable,
5. 0:16affordable and dispatchable electricity
6. 0:18while minimizing environmental impact.
7. 0:22Assal Energia is a world leader in the
8. 0:24power generation market. It has over 100
9. 0:27year experience in design and
10. 0:28manufacturer of rotating machine. Our
11. 0:31first in turbines date back to the
12. 0:33beginning of the 20th century. In the
13. 0:36last 50 years, we deliver [music] a gas
14. 0:38turbine, steam turbines and generator
15. 0:41for more than 1,000 power plants in the
16. 0:43world. All those machine have been
17. 0:46produced here [music] in the southern
18. 0:47energy quarter located in Genova, Italy.
19. 0:50Our heavy duty gas turbine are a perfect
20. 0:53example of innovation. By applying
21. 0:56leading edge technology in design and
22. 0:58manufacturing, they are among the most
23. 1:00efficient and operational flexible in
24. 1:02the market. They allow for an
25. 1:04affordable, reliable and [music]
26. 1:06dispatchable electric energy production.
27. 1:09Assad Energy is also the forefront of
28. 1:12fuel flexibility by developing hydrogen
29. 1:15and bofuel ready [music] turbines. Our
30. 1:18service business unit provides
31. 1:20continuous support to our customer by
32. 1:23extending the life of existing power
33. 1:26plant and by modernizing them. By doing
34. 1:28that we ensure leading edge efficiency
35. 1:31fuel flexibility by making them
36. 1:33compatible with hydrogen on other
37. 1:35lowcarbon fuels and operational
38. 1:38flexibility [music] allowing our
39. 1:40customer to meet the demands of the
40. 1:42evolving electrical market.
41. 1:48>> [music]
42. 1:53>> We are now inside a southern energy
43. 1:55affected. I'm in front of AE38 gas
44. 1:59turbine rotor. No matter the model,
45. 2:02every gas turbine is made up of the
46. 2:05safety elements. The rotor, the
47. 2:08mechanical heart of the turbine. This
48. 2:12rotating component is located [music]
49. 2:14inside the static external gate. The
50. 2:16entry part consisting to the compressor
51. 2:20which increase the pressure of the air
52. 2:21before the combustion chamber. The after
53. 2:24[music] part is the turbine itself
54. 2:28which are the mechanical energy from the
55. 2:31hot gases after the combustion and
56. 2:33transfer it to the rotor shaft. This
57. 2:36motion in then transferred to a
58. 2:38generator which turns into electricity.
59. 2:41Then we have the blades.
60. 2:44They are mounted around the rotor
61. 2:45[music] and these are among the most
62. 2:47critical component. Working together
63. 2:50with the [music] fixed blade mounted on
64. 2:52the outer casing, they enable the
65. 2:54thermodynamic cycle that converts the
66. 2:56chemical energy of the fuel into
67. 2:58mechanical energy. Last but not least,
68. 3:01we have the combuster where the fuel is
69. 3:04burned, heating the air and increasing
70. 3:07its pressure and temperature before it
71. 3:09enters the turbines.
72. 3:11This is another component where
73. 3:13engineering makes the difference
74. 3:15contributing to [music] both high
75. 3:17efficiency and low emissions.
76. 3:21Despite the huge size and weight g by a
77. 3:24machine of extreme precision, every
78. 3:27single blade is engineered and
79. 3:29manufactured with the same accuracy you
80. 3:32would [music] expect from a fine watch.
81. 3:34Clearances between rotating and fixar
82. 3:37are measured in fraction of millimeter.
83. 3:39Even though the components weigh several
84. 3:42tons,
85. 3:44this level of detail required [music]
86. 3:46advanced design, cutting edge material
87. 3:49and worldclass manufacturing [music]
88. 3:51skills.
89. 3:53Only with such precision can [music]
90. 3:55these technological models deliver the
91. 3:57power and reliability demanded by
92. 4:00[music] customer around the world.
93. 4:10>> [music]
94. 4:10>> At Ansalo Energia, we don't simply
95. 4:13assemble turbines. We turn raw steel
96. 4:16into high-tech components through
97. 4:17state-of-the-art processes, enabling the
98. 4:20production of gas turbine, steam
99. 4:22turbines, and generator that power the
100. 4:24energy of the future.
101. 4:27Air Force are the technological her of a
102. 4:29gas turbine. Every blade plays a crucial
103. 4:32role in efficiency and performance. Here
104. 4:36we will follow the process of creating
105. 4:38compressor blades both rotating and
106. 4:40stationary to a meticulous sequence of
107. 4:42advanced machining and rigorous quality
108. 4:45check. From a simple metal bar to a high
109. 4:48precision compressor blade, the journey
110. 4:51is a meticulous sequence of advanced
111. 4:52machining and street quality checks. It
112. 4:55all begins with cutting the robot to the
113. 4:58right end ready for shaping on our
114. 5:00computer numerical control milling
115. 5:02center. Then we craft the root which
116. 5:05will anchor the blade to the rotor or to
117. 5:07the caving. After the during when any
118. 5:10small resids are removed, the blades
119. 5:12take shape as the aerodynamic profile is
120. 5:15me. Quality is checked at every stage.
121. 5:19Dimensional inspection, spectrometrical
122. 5:21analysis to confirm the material
123. 5:23integrity and brushing to achieve a
124. 5:26flawless surface.
125. 5:28For the perfect finish, the blade goes
126. 5:30through barrel finishing, vibration
127. 5:32testing for moving blades, and magnetic
128. 5:34inspection to rule out even the smallest
129. 5:37crack. Finally, every blade under goes
130. 5:40visual check, final dimensional
131. 5:42verification, and surface roughness
132. 5:45cutting ensure it meets the exacting
133. 5:47standard required for performance and
134. 5:50reliability.
135. 5:53>> [music]
136. 5:53>> Each blade is mounted on the rotor shaft
137. 5:56or on the discs that compose it. The
138. 5:59machining of the disc is a highly
139. 6:01specialized process that combines
140. 6:03turning, grinding, baching and drilling.
141. 6:07Among these approaching plays a key
142. 6:09role. It created slots that will later
143. 6:12allow the blades to be assembled with
144. 6:14absolute precision.
145. 6:16This operation are not just about
146. 6:18shaping metal. They are about ensuring
147. 6:21resistance under extreme stress and
148. 6:24guaranteeing air tight tolerance.
149. 6:27Such precision is essential to achieve
150. 6:29outstanding reliability and efficiency
151. 6:32even when the discs rotate at speeds of
152. 6:34up to 3,000 revolution per minute. To
153. 6:37reach this level of performance,
154. 6:39machining relies on advanced tools
155. 6:41designed for accuracy and excellent
156. 6:43surface image. Now we'll move on to the
157. 6:46next stage.
158. 6:49>> [music]
159. 6:50>> Grinding is the most critical phase of
160. 6:52this process. It is performed on high
161. 6:55precision machine using ceramic bonded
162. 6:58abbrasive wheels profiled with a diamond
163. 7:00roll dresser. The process consist of
164. 7:04grinding the disc to create a serration
165. 7:07a radial toing that ensure precise
166. 7:10resistant coupling on each side with
167. 7:13tolerances in the order of 100 of mm.
168. 7:17This geometry allows for a perfect
169. 7:19connection among the different disc
170. 7:21composing the main shaft. Once
171. 7:23completed, the disc is totally inspected
172. 7:26to prevent any geometric anomalies.
173. 7:29This machining is essential to ensure
174. 7:32the highest standard for the rotor
175. 7:33shaft, the most mechanical stress
176. 7:36component of the gas turbine.
177. 7:40[music]
178. 7:43At Southern Energia, precision and
179. 7:45efficiency are not just goals. They are
180. 7:48our signature.
181. 7:50We achieve them through a unique blend
182. 7:52of cutting edge technology [music] and
183. 7:54worldclass expertise, mastering advanced
184. 7:58processes that take manufacturing to the
185. 8:00highest level.
186. 8:02Amaldi
187. 8:04electrical discharge machine stands out
188. 8:06as a true example of how innovation
189. 8:08[music]
190. 8:09and craftsmanship come together to shape
191. 8:12excellence.
192. 8:14What happens in this workshop may not
193. 8:16look spectacular at first sight, but it
194. 8:19is nothing short of extraordinary.
195. 8:22Electrical discharge machining or EDM is
196. 8:26what we call a nonconventional
197. 8:28manufacturing process.
198. 8:30Unlike traditional coupling, here the
199. 8:33material is not removed by direct
200. 8:35contact with the fool. Instead, it is
201. 8:38shaped by a series [music] of control
202. 8:41high frequency electrical sparks.
203. 8:44These sparks [music] generate tiny
204. 8:47localized melts that remove material
205. 8:50with extreme precision without the
206. 8:52electro ever touching the workpiece. But
207. 8:56innovation doesn't stop here. Laser
208. 8:59cladding is another advanced
209. 9:00manufacturing technology that use a
210. 9:02precisely control laser beam to melt a
211. 9:06metallic powder and fuse it into a
212. 9:08specific area of a turbine blade. Guided
213. 9:11by [music] 3D model, the process
214. 9:14achieves outstanding precision and
215. 9:16accuracy.
216. 9:18All the described process are essential
217. 9:21to ensure maximum precision and
218. 9:23reliability.
219. 9:25But technology alone is not enough. It
220. 9:28is thank to the skill and the [music]
221. 9:29dedication of our expert that these
222. 9:32processes fully express their value
223. 9:35ensuring the duration [music] is always
224. 9:37matched by quality, reliability and on
225. 9:40time delivery.
226. 9:46After exploring the workshop where a
227. 9:48rose steel is transformed to high-tech
228. 9:50components, it is time for the final
229. 9:54step of our journey.
230. 9:59To conclude this [music] visit inside an
231. 10:01Southerner GIA, we have chosen the
232. 10:04vacuum over speed cell.
233. 10:07This facility make it possible to test
234. 10:10the rotors once they are fully assembled
235. 10:13before being installed in the outer
236. 10:15casing.
237. 10:17This cell consists of a bunker with an
238. 10:20external reinforced structure measuring
239. 10:2320 m in length [music] and 8 m in
240. 10:26diameter.
241. 10:28This is one of the only five structure
242. 10:31with this size and capacity in the
243. 10:33world.
244. 10:35The rotor is introduced into the tunnel
245. 10:38and initially accelerated to achieve
246. 10:40stress relief. Once stabilized, the
247. 10:44tunnel is sealed and the air is removed
248. 10:46to prevent ventilation and thermal
249. 10:49effects.
250. 10:50The rotor is accelerated to 400
251. 10:53revolution per minute. Balancing is
252. 10:56performed by inserting correction
253. 10:58weights into dedicated slots if any
254. 11:01vibration is detected. Subsequently, the
255. 11:04speed is gradually increased to 20% over
256. 11:07speed up to 3,600 revolution per minute
257. 11:11to validate structural integrity
258. 11:14and ensure compliance [music] with the
259. 11:16highest standard.
260. 11:20What you have seen today [music] are
261. 11:22just some of the advanced technologies
262. 11:24we employ to manufacture and test our
263. 11:27products. They are the results of
264. 11:30precision, excellence, and relentless
265. 11:32[music] innovation.
266. 11:34Our mission is to contribute to
267. 11:36sustainable future for power generation
268. 11:39with pride [music] in our history,
269. 11:40professionalism in day-by-day commitment
270. 11:43to continuous improvement. Each
271. 11:45component, each process reflects our
272. 11:49dedication [music]
273. 11:49and our contribution to energy security
274. 11:52and transition.
275. 11:54Thank you for every being with us today.
276. 12:01>> [music]
277. 12:09>> Thank