Services
Manufacturing of gears and spares
Manufacturing
At TurboDyne, we manufacture precision components for critical rotating equipment
We manufacture gears, turbine blades, bearings, seals and spare parts for steam turbines, compressors, pumps, gearboxes, fans and blowers. Components are cut to customer drawings, or engineered from 3D scan data where drawings no longer exist. Each part is manufactured to original specification, or with an agreed material upgrade, and supplied with full material traceability.
Products
Engineered components and critical spares
- Gears, shafts and drive components
- Bull gears, pinions, gearwheel shafts, couplings and complete gearbox assemblies, single and double helical. Gear cutting and grinding capacity is extended through the group gear works.
- Turbine components
- Moving, stationary and guide blades, 5-axis milled and finished. Diaphragms, guide blade carriers and nozzle segments. Labyrinth seals, steam glands and inter-stage seals. Blade manufacture to 500 MW class through a technical partner.
- Bearings, impellers and valve components
- Journal bearings in cylindrical, multi-lobe and sleeve form, tilting pad and thrust bearings. Centrifugal, axial and high-speed impellers. Governing valves, servomotors and pump cartridges.
Processes
Manufacturing and inspection processes
- Materials
- Alloy and stainless steels, chrome and nickel alloys including Inconel, bronzes and bearing white metals, ordered against certification.
- Machining
- 5-axis CNC milling, heavy turning and boring, cylindrical and surface grinding.
- Gear cutting and grinding
- Hobbing and shaping followed by grinding, with tooth profiles checked against AGMA and ISO accuracy classes.
- Heat treatment and welding
- Stress relief, hardening and tempering to specification, with qualified welding procedures for build-up and repair.
- Inspection
- Dimensional verification, positive material identification, hardness testing, and ultrasonic, magnetic particle and dye penetrant inspection.
- Balancing
- Rotating parts dynamically balanced to ISO 1940 and released with a certificate.
Gear works
Gear cutting, grinding and gearbox assembly
Teeth are hobbed or shaped and then ground, and profiles are checked on a gear tester. Through the group gear works we build complete gearbox assemblies for turbine, hydroelectric, kiln and process drives, single and double helical. The units below are representative of the range built to date.
20 MW turbine gearbox
High-speed set for a turbine drive, casing opened on the helical bull gear, pinion and journal bearings.
5,000 kW hydroelectric gearbox
Built for a hydro set and assembled for despatch, with the flanged output coupling forward.
Four-stage kiln gearbox
Steel mill kiln drive. Four reduction stages of double-helical gearing, laid out before assembly.
1,000 kW turbo gearbox
Speed-increasing set for a turbo drive, assembled and painted, instrument terminal box on the casing.
500 kW gearbox
An early build, photographed on test with dial indicators set over the bearing housings.
Assembled and coupled
A finished gearbox on the shop floor, coupled to its drive motor and wrapped for shipping.
Gear work
Gears, pinions and gearwheel shafts
Double-helical bull gears and their pinions, cut, ground and set up on their bearing journals.
Component range
Parts manufactured at Jubail
Made to drawing, or engineered from 3D scan data where no drawing exists.
- Moving blades
- Stationary blades
- Turbine blade assemblies
- Guide blade carriers
- Nozzle and L ring assemblies
- Diaphragms
- Diffusers
- Turbine casings
- Compressor rotors
- Impellers and geared shafts
- Bull gears
- Gearwheel shafts
- FD and ID fan shafts
- FD fans
- ID fans
- 600 MW class tilting pads
- Thrust pads
- Multi-lobe journal bearings
- Inter-stage seals
- Sealing fin strips
- Spacer bands
- Oil seals
- Spherical ceramic washers
- Governing valves
- Governing valve seats
- Solenoid valves
- Servomotors
- Hydraulic manifolds
- Pump cartridges
The workshop
Cut, measured and balanced at Jubail
Machining, dimensional inspection, NDT and dynamic balancing are carried out in our own workshop. A component made here rather than ordered abroad loses the shipping and customs time from its delivery date, and the work stays in the Saudi supply chain that Vision 2030 sets out to build.
Gallery
Finished components
Turbine blades and nozzle segments, diaphragm halves, journal and thrust bearings, threaded sleeves, stub shafts, bronze bushes and geared shafts.
How we work
From enquiry to dispatch
- 01Enquiry & Planning
- 02Reverse Engineering & Design Validation
- 03Precision Machining & Fabrication
- 04Quality Inspection & Testing
- 05Packing & Delivery Support
Sectors
Industries we serve
- Power generation
- Oil and gas
- Refineries and petrochemicals
- Fertilisers
- Steel and cement
- Mining
- Aerospace and defence
Quality verification and certification
Components are manufactured to API, ASME and ISO requirements. Material is traced to the job, every part is verified against the drawing or the scanned model, and manufacturing is released with material certificates, dimensional inspection reports, NDT results and balancing certificates. Send us the drawing and equipment details, or the component itself, and we will reply with scope, lead time and price.