Heavy Fabrication for the Power Generation Sector
The power generation industry relies on massive equipment that must operate under extreme thermal stress, high pressure, and relentless vibration. Whether for a natural gas combined-cycle plant, a nuclear facility, or a coal-fired power station, the structural integrity of these components is absolutely critical.
At Openex, our 180-acre facility is perfectly equipped to manufacture colossal power plant components. We combine heavy plate forming, deep-penetration AWS/ASME certified welding, thermal stress relief, and ultra-precise 5-axis CNC machining to deliver turnkey generator frames, turbine housings, and condenser shells that weigh up to 250 tons.
Commonly Manufactured Power Equipment
⚡ Stator Frames & Generator Housings
Massive welded and machined frames that house the electrical generation core. We ensure perfect concentricity and structural rigidity to prevent vibration.
⚡ Steam & Gas Turbine Casings
Heat-resistant heavy fabrications built to withstand extreme internal pressures and temperatures. Fully machined for airtight flange seals.
⚡ Exhaust Plenums & Diffusers
Large-scale ductwork and exhaust management systems. Fabricated from high-grade stainless and heat-resistant steel to manage extreme exhaust gas heat.
⚡ Condenser Shells
Colossal pressure vessel cylinders fabricated with thick carbon or stainless plate, rolled, welded, and heavily inspected using NDT.
Power Plant Fabrication Capacities
| Maximum Lifting Capacity | 250 Tons (Crucial for massive generator frames) |
|---|---|
| Max CNC Machining (L x W) | 25,000 mm x 6,000 mm (Gantry Milling) |
| Materials Processed | Carbon Steel, Stainless Steel (304/316/310S), Inconel, Heat-Resistant Alloys. |
| Welding Certifications | ASME Section VIII, AWS D1.1, EN 1090, ISO 3834-2. |
| Non-Destructive Testing (NDT) | Radiographic (RT), Ultrasonic (UT), Magnetic Particle (MT), and Dye Penetrant (PT). |
The Manufacturing Lifecycle
We utilize large-capacity press brakes and heavy plate rolling machines to form the massive cylindrical and conical sections of the turbine shells and exhaust plenums.
Because power components endure high vibrational fatigue, our certified welders utilize Submerged Arc Welding (SAW) and highly controlled multi-pass welding to ensure 100% joint integrity.
Large weldments inevitably hold internal stress. We load the completed frames into our massive on-site heat treatment furnaces for Post-Weld Heat Treatment (PWHT) to guarantee dimensional stability.
The stress-relieved frames are moved to our gantry mills. We precisely machine mounting pads, bearing journals, and flange faces, followed by full 3D laser tracker dimensional inspection.