Turbine Services Ltd Group Engineering Presentation Turbine Services

Turbine Services Ltd, Group Engineering Presentation

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts OVERVIEW Engineered more than 700 turbine parts including 50 rotating blades 30 stationary vanes Developed 7 complete product lines namely MS 3002, MS 5001, MS 5002, MS 5001 NT, MS 6001, MS 7001, MS 9001 Product-to-market development cycle as low as 14 months for capital parts and even lower for other turbine parts State Of The Art Equipment To Design & Analyze Turbine Components

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts REVERSE ENGINEERING DATA COLLECTION REVERSE ENGINEERING VALIDATION OF DESIGN

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts REVERSE ENGINEERING • • • DATA COLLECTION TECHNIQUES/ METHODS Point Cloud Data Collection • White Light Scanner – GOM • Laser Scanner- Nvision Conventional Data Collection • Coordinate Measuring Machine (CMM) • Verniers, Calipers, Height Gauge Material • Xray Material Analyzer Thicknesses, Hardness etc • Ultrasonic probe • Hardness Tester Extra/ Hidden Features • XRAY • Boroscope Analysis REVERSE ENGINEERING VALIDATION OF DESIGN

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts REVERSE ENGINEERING • • • 3 D Modeling and Design 2 D Drawing Material Specification Process Specification Inspection Report DATA COLLECTION REVERSE ENGINEERING VALIDATION OF DESIGN

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts REVERSE ENGINEERING VALIDATION OF DESIGN • Prototyping • Stereo Lithography Model (SLA) • Finite Element Analysis DATA COLLECTION REVERSE ENGINEERING VALIDATION OF DESIGN

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts RESEARCH & DEVELOPMENT BRUSH SEAL Direct replacement to OEM Brush Seal Technology Improves Efficiency with advanced sealing 1. 0% output 0. 5% heat rate Improved Durability Increased Efficiency Reduced Leakage

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts RESEARCH & DEVELOPMENT Technology The SL+™ package, engineered and manufactured by TSL® includes newly designed combustion parts with improved features including: • Improved clearance • Addition of wear resistant materials • Thermal Barrier Coating (TBC) Advantages • Extension of gas turbine Combustion Inspection interval • Reduction in Maintenance and Refurbishment Costs • Increase service life of parts

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts MANUFACTURING ASSEMBLY MACHINING CASTING COATING

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts MANUFACTURING CASTING THE CASTING PROCESS MACHINING COATING

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts MANUFACTURING CASTING THE CASTING PROCESS MACHINING COATING

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts MANUFACTURING CASTING MACHINING COATING ALLOYS • All TSL blades and vanes are manufactured with Super alloys o Super Alloys are a class of material that represent the highest level of alloy chemistry and process metallurgy in current aerospace and land based power generation industry. Super alloys run at 90% of their melting point. • All hot section part manufactured by TSL are prepared from controlled virgin/remelt ratios using Vacuum Slag Remelt (VSR) or Electro Slag Remelt (ESR) to ensure cleanliness of alloy • TSL requires certified chemical/mechanical properties of sample coupons or test bars for each master melt lot to ensure the integrity of the alloy. • Manufactures both Equiax and Directionally Solidified parts

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts MANUFACTURING CASTING TSL TOOLING • All capital parts tooling are owned by TSL • Each capital part has a complete set of tooling • Wax injection tooling • Assembly fixture • Checking gauges HEAT TREATMENT • Castings are thermally processes for optimum strength QUALITY CONTROL PLAN • TSL requires first article sample piece to validate suppliers’ casting process • Supplier submit process demonstration report • Independent testing of first article to validate supplier’s process • Regular on site audit to ensure uniformity of processes MACHINING COATING

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts MANUFACTURING CASTING CONVENTIONAL MACHINING • Parts are machined to finished dimensions using • Stress free grinding, Turning, Milling • TSL owns all machining tooling NON CONVENTIONAL MACHINING • Internal Cooling holes and other features are inserted by • Electric discharge machining (EDM) • Shaped Tube Electrochemical Machining (STEM) • Electrochemical Machining (ECM) Internal Cooling holes are used to keep the core material of the blades and vanes cool at running temperatures QUALITY CONTROL PLAN • • TSL requires first article sample piece to validate supplier’s process Supplier submit manufacturing process plan TSL conduct internal dimensional inspection to validate part Regular on site audit to ensure uniformity of processes MACHINING COATING

Turbine Services Limited Replacement Parts for GE Design Large Frame Gas Turbine Parts MANUFACTURING CASTING MACHINING COATING TSL applies all the updated coating to our turbine parts namely: • Thermal Barrier Coating TBC • For enhanced heat resistance • Chemical Vapor Deposition (CVD) Aluminide • In cooling passages to resist corrosion and oxidation • Stellite strips inserts by High Velocity Oxy Fuel (HVOF) • Increases wear resistance of parts by acting as sacrificial wear agent • Duplex Coating Systems (MCr. Al. Y, Ni. Co. Cr. Al. Y, Co. Ni. Cr. Al. Y) • Applied to allow blades and vanes to operate at high temperatures by resisting oxidation and corrosion • Preserves the strengthening mechanisms of the base material • Plasma Coating • Increases corrosion resistance. TSL also Shot Peen blades to add compressive surface stress the structure and HIP (Hot Isostatic Pressing) to eliminate microporosity.

Turbine Services Ltd, Group Delivering Quality Anywhere In The World Conclusion Largest Non-OEM Manufacturer In The World Highly Experienced Engineering Personnel Unequaled product-to-market development cycles State of The Art Engineering Capabilities Manufacture parts with the latest turbine manufacturing technology Stringent Quality Control Turbine Services, Ltd. Group 41 Old Gick Road, Saratoga Springs, NY 12866 Phone: 518 -583 -6191 – Fax: 518 -583 -4094 Email: sales@turbineservices. com Web: http: //www. turbineservices. com