Wuhan Boiler Co. Ltd. -

Company description

Wuhan Boiler Company Ltd.(hereafter called WBC) is holded by Wuhan Boiler Group Company Limited whose predecessor is Wuhan Boiler Work, Wuhan Boiler Company limited has had its B Shares listed on the Shenzhen Stock Exchange. The company is located in Wuhan city, HuBei province, P.R.C. The Yangtze River flows from west to east and the Jingguang railroad runs from north to south. WBC is at a beautiful place with convenient transportation. WBC is one of the big enterprises in P.R.C. who engaged in manufacturing utility boilers, industrial boilers, special boilers, pressure vessels, valves and nuclear facilities for civil use, one of the five biggest power plant boiler manufacturers as well as the largest manufacturing base of environmental special boiler. WBC has tremendous strength in technology and can provide performance guaranteed product, the class of WBC¡¯s fund qualification is AAA.
WBC sales and manufactures mainly large-scale utility boilers, ARI pressure vessels and special boilers as well as engineering contracted projects. The company has been awarded A class boiler qualification of design and manufacture, III pressure vessel qualification of design, ARI class pressure vessel qualification of manufacture and qualification for pressure parts used in nuclear plant, it has also been identified as the first group of de-sulphurization bases.
Since recent years, WBC has concentrated its efforts on technology and management innovation with increase in economy efficiency and improvement in key know-how, the market share and effects of its principal products went up much higher, especially in the research and development of environmental boiler and special boiler.2. Digital display of WBC
l Established in 1953 and put into operation in 1956
l Identified as one of the 100 modern system enterprises in 1995
l Wuhan Boiler Company Limited listed its B shares on Shenzhen
Stock Exchange in April,1998(abbreviated share name£ºWuguo B£¬
code£º200770)¡£
l Present year production capacity£º
Utility 5000MW¡¢Industrial Boiler500 Ton
l The manufacture shop was 220,000 square meters large
£¨including Drum and vessel fabrication shop: 33467square meters, and tube fabrication shop:65325 square meters£©
l Staff:2766 £¨including high and middle rank technician: 378£©
l Been awarded U and S stamps and certificates from 1990
l Awarded ISO 9001 certificates from 1995
l Utility boiler output£ºaccumulated to 39640MW£¬among which£º
410t/h£¨allocated with 100MW£© 93sets 9300MW in total
125MW¡«150MW 21sets 2820MW in total
670t/h£¨allocated with 200MW£© 44sets 8800MW in total
300MW series 57sets 17520MW in total
600MW series 2sets 1200MW in total
3. Human Resource
3.1 Technicians in each speciality
Engineers and technicians: 704
Including: Senior engineer: 116
Engineer: 262
3.2 Engineering technicians : 423
3.3 Staff of R&D : 60
Including: senior engineer: 24
Engineer: 19
3.4 Staff of Technology Department: 165
Including: senior engineer: 37
Engineer: 67
3.5 Welding technicians:
Senior engineer and engineer: 27
Qualification welder: 261
3.6 Inspector: 208
Including: senior engineer and engineer: 14
3.7 Non-destructive examination technicians: 80
3.8 Staff of material research institute: 74

4. Technology Support
WBC is granted as ¡°one of the 100 strongest industrial technology development enterprise in China¡± by State Economy & Trade Committee and State Statistics Bureau. WBC¡¯s R&D proper-technical center was included by the State Economy & Trade Committee, State Taxes Bureau and Governmental Customs Agency in the First Batch of the Forty Enterprise Technology Centers in the PRC in 1993.
The company will focus on the research and development of large size power station boilers, CFB boilers, large size soda recovery boilers, utility equipment using new source of energy, nuclear facilities for civil use, gas de-sulphurization equipment for large size power station boiler, software development for boiler design, performance research on special type of steel, etc.
4.1 Wuhan Boiler Company Limited imported technology from ABB-CE company, including 250MW to 630MW drawings, design and calculation software, completion technology procedure, quality guarantee and installation document, etc. WBC signed agreement on large size coal-fired boiler with ALSTOM American Branch (the original CE company) in 2003.
Explored extended cooperation with international famous energy companies, such as Germany BABCOCK, British MBEL company, Finland AHLSTROM company, Germany ALSTOM-EVT and conducted co-design and sub-contract manufacture on concrete projects.
4.2 The design and research institute of WBC is responsible for the design of boilers and other products.
There are 8 speciality groups in the institute such as boiler proper design, combustion system design, steel structure design, new product development group, pressure vessel design etc.
4.3 Computer Aid Design is using in many areas and more than 98% drawings are drawn by CAD.
Many computer programs such as the Thermodynamic calculation, strength calculation, pipeline stress analysis, steel structure calculation have been developed by the institute itself and can meet the requirement of modern big boiler design.
4.4 Technology department is responsible for product technology and technique group is set in each division and workshop.
4.5 WBC has a technology center which research and develop all kinds of new products. The center is one of 40 enterprise technology centers approved by National Economic and Trade Committee, can enjoy tax-free preferential policy.

Location

Products

The kinds of utility boiler
According to Capacity:
35t/h,50t/h,65t/h,75t/h,110t/h,120t/h,130t/h,
220t/h , 400t/h ,410t/h,670t/h, and 1025t/h,1246t/h
According to Pressure:
3.82MPa, 5MPa, 5.3MPa, 6.3MPa,
9.8Mpa 13.7MPa,and 16.66Mpa
According to Fuel:
oil, gas (natural gas,high oven gas,coke over gas,CO),
bituminous coal, lean coal, lower rade coal, lignous coal
and anthracite.
According to Combustion form:
grate boiler, coal powder boiler and fluidized bed boiler,
cyclone boiler
According to the form of slag-removed:
boiler with solid slag removed,
boiler with slag removed in liquid form.

Services

After sale service is important stage in the company sales. In order to strengthen service, the company has set up a "Customer Service Department".
With the thought of "Customers First", the customers service department is responsible for providing all service after sales and is authorized to organize related persons for customer servicing:
Detailed service is mainly as follows:
7.1 Send representative resident on the site
7.2 Send technical personnel for installation instruction and installation supervision.
7.3 Resolve all problems and disputes happened in the process of despatch.
7.4Resolve possible problem of design or process of manufacture quality,including repairment on the site ,exchange,reparation,etc.
7.5 Assist to resolve all kinds of problem caused by customers themselves.
7.6 Help customer with commission and operation.
7.7 Answer all questions from customer
7.8 Help customer in personnel training and send technicians to demonstrate techniques on the site.
Customer's Service Department established the system of strict award and punishment, render the ideas concerning the service following the traces of products, service in time, service in working site, and assistant service etc. For the excellent service, WBC has gained the title of Excellent Service Company of National Mechanical and Electronic Ministry.

Materials

• Composite material
• General cast steel
• Iron
• Stainless steel
• Nickel (alloys)

Special production facilities

• Major Equipment
  5.1.1 Forming Equipment:
  There is a 32¡Á8000 plate rolling machine, which can hot roll steel plates as thick as 90mm and a 24000KN¡Á4000MM three roll plate rolling machine, which can hot roll plates as thick as 210mm.
  Hydraulic press: capacity is 1000t. Plate thickness up to 90mm can be hot pressed.
  5.1.2 Heat Treatment Equipment:
  The works now has a annealing furnace, a 4.5m¡Á4.5m¡Á10m drum head heating furnace, a 4.5m¡Á4.5m¡Á25m annealing furnace controlled by microcomputer.
  5.1.3 Welding Equipment:
  The company has 29 different automatic welding machines, 80 manual argon arc-welding machines, 326 manual welding machines (including 194 DC welding machines) and 2 acoustically controlled pulse plasma welding machines.
  We can make longitudinal and circumferential weld joints of drums, butt joints of headers, and various kinds of butt and corner weld joints of tubes and pipes.
  In Recent years, we have introduced from the German Babcock Co. TIG welding machines, twin tube welding machines, and portal welding machines for the tube coil production line and membrane wall production line and automatic submerged arc corner joint welding machine for welding header nozzles. Our welding equipment for tube welding and making corner joints in headers has reached the advanced international level.
  5.1.4 Tube Bending Equipment.
  Two automatic bending tube produce lines, including one bending tube line imported from Deutsche Babcock.
  The membrane waterwall bending machine is imported from Deutsche Babcock.
  R/D=1 CNC tube bending machine is imported from British Addison.
  In addition to the above production lines, the company has 10 other tube bending machines, including a hydraulic pressure tube bending machine and a large, medium frequency induction heating tube bending machine.
  5.1.5 Mechanical Tools
  There are 414 machine tools in our company including a ¦µ3¡Á10M and a ¦µ1¡Á8M lathe, horizontal lathe ¦µ3.4M, ¦µ100 boring machine, a ¦µ60 floor boring machine and a 1.6¡Á6M double housing planer, ect.
  5.1.6 NDE Equipment
  4MeV line accelator, 16 x-ray machines(the biggest one is a 420kv machine), one 200kv industrial TV x-ray machine, two ¦Ã-ray machines ZV192, 20 ultrasonic flaw detectors, 5 1000A©¤2000A magnetic particle flaw detectors, etc.
  5.1.7 Physical and Chemical Testing Equipment
  We have a mechanical property laboratory equipped with a complete set of physical and chemical test equipment. In addition, there is a high temperature laboratory which tests high temperature creep strength of materials and equipments fitting for the tests on low temperature. Infrared C&S detector imported from U.S., ICP emission spectrum machine imported from France.
  5.1.8 Hoisting equipment
  The works has 41 overhead cranes with capacities form 15t to 100t.
  5.1.9 Other equipments
  Type C bending machine
  Small R press machine
  Tube end forming machine
  Hot TIG welding machine ¦Ä= 12mm
  5.1.10 Except the initiated membrane wall production line and tube coil production line, WBC has four membrane wall production lines and second tube coil production line and can fully meet the requirement of 300MW, 600MW boiler manufacture.
  5.2 Our company imported 30 pieces of equipment of 18 different types for the tube coil production line, membrane wall production line, and header manufacturing.
  It is shown in practice that these imported equipments have reached the advanced international level.
  5.2.1 Tube coil production line.
  1# tube coil production line includes tube preparation, straight tubes welding, x-ray flaw detection, tube bending and necessary storing, turning over and delivery operations. Major equipment imported are the TIG welding machine for circumferential welds in straight tubes and CNC left and machine for circumferential welds in straight tubes and CNC left and rightward tube bending machine from German Babcock Company, and screen type flaw detection equipment from Denmark Andrex Company. The production line can produce econonizers, superheaters and reheaters of ¦µ25mm--¦µ63.5mm, d<7.1mm, L<55m with an annual output equivalent to 1200MW.
  2# coil tube production line includes TIG straight tube butt joint production line, TIG/MIG straight tube butt joint production line, X-TV examination production line, CNC coil tube bending production line. It can produce maximum straight part length is 14m, it¡¯s open length is 55m, maximum diameter is ¦µ63.5mm, thickness of tube is <12mm, R/D=1.18.
  Tube bending machine is computer numerically controlled on four coordinates. It has systems for vertical pressing,
  diespeparating and preventing. It can do R/D=1.18 tube bending, left and rightward tube bending. It is in an advanced position in the country. (Smallest R/D formerly made in China is 1.5)
  The vertical pressing assures the quality of tube bends. The diameter variation of tube at bends is no more than 0.5mm. Thinning of bend outside tube wall is small and ideal, and occupies an advanced position in China.
  For TIG welding, the welds are up to standard and without any repair are more than 99%.
  WBC has developed an automatic programming system for tube coils. It can do programming, checking, diagramming, printing and punching automatically.
  The production line uses a 200kv screen type x-ray machine. Its maximum detectable thickness is 10.3mm. Its sensitivity is 1.5%The machine can inspect, photograph, film and mark out defective welds continually.
  5.2.2 Membrane wall production line
  It consists of equipment for tube preparation, tube sootblow system, flat steel treating, submerged arc welding of twin tubes, membrane wall elements cutting, bending, self made equipment for material feeding, turning over and storing ect. The production line produces membrane wall elements of width¡Ü3m with tubes ¦µ26.9--¦µ101.6mm in diameter and steel bars 9--100mm wide.
  Babcock 800-4 twin tube welding machine and the model 3000 portal welding machine guarantee a high quality and high efficiency.
  Membrane walls produced on the line were all up to international standard in weld penetration, width variation, pitch variation, bend, tube roundness, weld under cut, weld porosity, etc.
  5.2.3 Equipments for Header Production
  Imported equipment--B3 numerically controlled tri-spindle drilling machine for header production.
  a. Major data of the equipment:
  Number of spindles: 3
  External diameter of headers:¦µ100--¦µ900mm
  Maximum length of header: 12M
  Maximum weight of header: 15T
  Maximum diameter of drill: ¦µ80mm
  This equipment can meet the requirements of drilling in various kinds of headers.
  b.The machine adopts double coordinate computer controlling operations such as hole positioning and mark punching are no more needed.
  Drilling and weld groove preparation can be done simultaneously with a compound cutting tool.
  5.2.4 The Imported Header Nozzle Welding Machining Equipment
  Equipment including:
  Inside hole welding head: 1
  Submerged arc welding head: 2
  Carry on the inside hole welding hase of header nozzles with the TiG impulse welding, then realize the second automatic welding for covering the surface with the submerged arc welding.
  The equipment has automatic resistance heating installations to preheat the nozzles and control accurately their temperature before welding.
  
  6. Quality Assurance
  6.1 A brief account of quality control
  Wuhan Boiler Company has obtained ASME ¡°S¡±&¡°U¡± stamps and certificates authorized by the Boiler and Pressure Vessel Committee of the American Society of Mechanical Engineers in May 1990.
  In 1995, WBC has gained ISO9001 Certificate.
  6.2 Quality Assurance System
  6.2.1 Diagram of product quality assurance system
  (attached hereafter)
  6.2.2 Quality control
  According to standard ISO 9001, WBW has been perfecting the quality control system including design, technology, material, weld, non-destructive examination, chemical and physical inspection, inspection, equipment measurement, and carry out total quality control in all product stages from material, investigation, design and after-sales service, in all respects and by all members. There is the first level document including all kinds of procedure document including all kinds of procedure documents, 159 regulations, 2 items 178 kinds management standard, 900 items total 3000 clauses work quality standard. The third documents of system include 391 kinds original record, 145 kinds table accounts, 71 kinds report and 16kinds computer information management system. <<Quality Manual>> was formulated in 1983, and it is the norm of our factory quality assurance. Now the seventh edition has been formulated according to the requirements of ASME and standard ISO 9001.
  Our factory has appointed quality assurance engineers and quality responsibility engineers to put into effect the quality and technology responsibility system. A sound 3-level quality management network has been set up in the works and full-time quality management personnel have been disposed in main divisions of the company.
  At the same time, product quality and inspection quality are supervised by touring quality inspectors appointed by the president. So a double-track quality control is carried out in the company.