Overview of Manufacturing Capabilities – Turbine Division
The Turbine Division focuses on the R&D and manufacturing of critical components for large high-end compressors. It has established a full-process manufacturing capacity covering all procedures for compressor parts, including sheet metal processing, welding, heat treatment, cold machining, special fabrication, assembly and full-scale test runs.
Its core high-end processing equipment includes multi-axis CNC cutting machines, vacuum furnaces, floor-type boring & milling machines, CNC gantry milling machines, turn-mill composite machining centers, 5-axis linkage machining centers, electrical discharge machines (EDM), 3D printing systems and vacuum electron beam welders. A national-level test run center is also established on-site. The detailed manufacturing capabilities by process are specified as follows:
1. Cutting & Blanking Capacity
The CNC flame cutting machine achieves a maximum cutting thickness of 400 mm with a cutting envelope of 12 m × 6 m. Equipped with a dual-torch system for automatic bevel cutting, it delivers a cutting surface roughness of Rz300.
A large flame cutting robot is deployed for 3D spatial cutting of welded casing complex structures, with a cutting surface roughness of Rz200.
2. Forming Capacity
A 2,000-ton C-frame hydraulic press with automatic clamping and in-line inspection enables flattening of 300 mm-thick horizontal flanges.
An extra-large pre-bend-free plate rolling machine with a working range of 4000 mm × 120 mm can complete roll forming of inner and outer shell plates up to 120 mm thick without pre-bending.
3. Heat Treatment Capacity
Vacuum heat treatment furnaces, pit furnaces and box furnaces are available for thermal processing of components such as φ2000 mm impellers and 9 m-long main shafts. The maximum heating temperature reaches 1350 °C, supporting integral heat treatment of key parts including impellers, main shafts and casings.
4. Welding Capacity
A full spectrum of welding processes is available: manual arc welding, submerged arc welding, TIG (GTAW), MIG (GMAW) and vacuum electron beam welding. The division is capable of fabricating welded 2D and 3D compressor impellers as well as large casings. Multiple industrial and collaborative welding robots automate welding for partial structural components of compressor casings.
5. Boring & Milling Machining Capacity
More than 20 boring & milling centers including model 260 floor borers and 20-meter CNC gantry mills are installed, offering a machining travel of 20000 × 8000 × 8000 mm. The rotary worktable bears a maximum load of 350 tons, with linear machining accuracy of 0.01 mm and rotary indexing accuracy of 0.002°.
Auxiliary attachments include AC-axis CNC milling heads, right-angle heads, universal angle heads, extension heads and facing heads, enabling integrated high-precision compound operations (boring, milling, drilling, counterboring, reaming, tapping) for large box-type components such as compressor casings.
6. Impeller Milling Capacity
Over 20 3-axis and 5-axis machining centers of various configurations (vertical cradle, horizontal swivel head, gantry swivel head, rear-wall swivel head) are deployed. The maximum machinable impeller measures φ2200 mm with a weight of 18 tons, supported by full 5-axis linkage machining. Positioning accuracy reaches 0.008 mm, and the machined surface roughness meets Ra ≤ 1.6 μm.
7. Main Shaft & Rotor Machining Capacity
More than ten sets of equipment including CNC lathes, CNC external cylindrical grinders and turn-mill composite centers deliver complete machining workflows for main shafts: rough turning, finish turning, grinding and milling. The maximum machining dimension is Φ2500 mm × 10000 mm with a workpiece load capacity of 40 tons. Fitted with angular milling heads, the machines realize 5-axis processing and integrated turn-mill-grind one-piece forming of compressor main shafts.
8. Rotor Overspeed Spin Test & Dynamic Balancing Capacity
Over 20 high/low-speed dynamic balancing machines and overspeed spin testers are equipped. The maximum balancing envelope is φ3600 mm × 12 m with a maximum workpiece load of 50 tons. The overspeed test facility accommodates rotors up to φ2300 mm and 6.3 tons in weight.
9. Full Compressor Unit Test Capacity
A national-class compressor test base features a span of 36 m, height of 28 m and a maximum lifting capacity of 300 tons. It supports full-speed, full-pressure and full-load operation tests and aerodynamic performance calibration under three driving modes: 30 MW gas turbine drive, 50 MW electric motor drive and 10 MW steam turbine drive. This facility is the sole domestically owned test base for large turbocompressors with internationally leading technical standards.
