On September 2022, our company was assigned with the major overhaul and repair of the pumping units of Combined Cycle Unit No5, at PPC Lavrion Station.
In total, 2 high pressure feedwater pumps, 1 intermediate pressure feedwater pump, 2 seawater circulation pumps and 2 condensate pumps were overhauled according to makers instructions and supervision by Flowserve technician.
The pumps were fully dismantled, and their components went through rigorous inspections in terms of dimensional measurements, run-outs, NDT and all strategic parts were Reversed Engineered (chemical analysis, hardness analysis, 3-D scanning and 3-D modeling).
During the repairs, the customer’s spare parts were used according to availability, and in the cases where they were not available, our company manufactured new ones through reverse engineering or repaired the damaged parts, by Laser Cladding, thus saving precious time and costs for the customer.
Some of the works carried out included the manufacture of new ORKOT bearings for the seawater pumps as well as coupling sleeves and shaft sleeves for the condensate pumps and CARBON bearings. The restoration of critical surfaces was restored by machining on our CNC machines and where necessary, Laser Cladding build-up was applied followed by machining.
After completion of the works in our facilities the pumps were fitted back to their working positions and tested by PPC Lavrion Station personnel.
it is worth mentioning that the performance of the station improved by 3% (see attached link https://energymag.gr/news/energeia/ilektrismos/dei-afxisi-ischyos-kai-apodosis-efere-i-syntirisi-sto-lavrio-v/)