Industrial Gas Turbines Aftermarket Parts, Repairs & Services
Industrial Gas Turbine New Parts Industrial Gas Turbine Repair Aftermarket Field Services
Industrial Gas Turbines Aftermarket Parts, Repairs & Services
1 About Us 2 Industrial Gas Turbine New Parts 6 Industrial Gas Turbine Repair 9 Aftermarket Field Services
About Us PW Power Systems, Inc. (PWPS) is a world leader in developing and manufacturing energy solutions for power generation offering products for aero-derivative and industrial gas turbines. PWPS™ offers a full range of maintenance, overhaul, repair and spare parts for other manufacturers’ gas turbines with specific concentration on the high-temperature “F” class industrial machines. PWPS also offers quick turnaround for parts and repair services utilizing the latest in component repair technology integrated from Pratt & Whitney® Global Aftermarket Service expertise. PW Power Systems is committed to providing high-quality solutions for the distributed energy market that increase energy productivity, energy reliability, and operational savings for our customers.
1
Industrial Gas Turbine New Parts PW Power Systems designs, reengineers and manufactures components for use in land-based Industrial Gas Turbine (IGT) applications. As part of the portfolio of components and services available, PWPS produces and repairs replacement parts for the hot gas path (HGP) from other OEMs of large-frame gas turbines. The PWPS™ components are manufactured using Pratt & Whitney® proprietary alloys and coatings. These materials, coupled with aerospace and industrial design technology and quality systems, enable users to install these components and operate their equipment with no degradation in machine performance while realizing improved durability of the hot gas path components. PWPS™ solutions allow customers to develop a degree of confidence that is unparalleled in the industry. 2
PWPS experience with HGP parts and repairs is based on comparisons of distress modes observed in the fleet. At PW Power Systems, it is our goal to provide value- based gas turbine solutions for our customers by incorporating customer feedback, component optimization and the advantage of over 80 years of technology development from our extensive hightemperature aviation heritage. PWPS is leveraging Pratt & Whitney® world-renowned hot section engineering to address the needs of the industrial gas turbine customer. PWPS has an extensive proven history of producing industry-leading technological solutions. We utilize this advantage by applying our proprietary technology to create new and innovative solutions for our industrial customers.
Engineering Standard Work The Foundation for Quality OEM Part
Industrial Gas Turbine Enhanced New Parts
Scanned Data
Scanning
Initial CAD Model
Systems & Aero Analysis
Advanced Proprietary Technology includes: • High-Temperature Technology • Proprietary Alloys • Metallic Coatings • Ceramic Coatings • Film Cooling • Multidisciplinary Optimization • Tip Clearance Material Systems • Advanced Computational Modeling Techniques
60 HZ Portfolio offering
Design/Analysis Multi-disciplinary Optimization
• Frame 7FA.03 1st, 2nd and 3rd Stage Buckets, Nozzles & Shroud Blocks • Frame 7FA.03 DLN 2.6 Transition Pieces, Liners, Flow Sleeves, Liner End Cap, Fuel Nozzles • Frame 7EA 1st, 2nd and 3rd Stage Bucket
50 HZ Portfolio offering HighTemperature-Class hardware
Final Definition
• STG5-4000F (V94.3A4x) Hot Gas Path Components • 1st, 2nd, 3rd, 4th Stage Blades & Vanes • Blade Outer Air Seals (BOAS) New PWPS™ Part
“PWPS has surpassed over 1.8 million hours of accumulated run time on its Frame 7FA.03 (7FA+e) HGP components.” 3
Product Development Process Robust intellectual property strategy integrated into reengineering design
Project Launch
Engineering Analysis
Prelim IP Assessment
Detailed Design
Preliminary Design
Metrology
Production
Features List
IP Risk Identification
Final Clearance
IP Due Diligence Process
PW Power Systems™ Experience and Technology Differentiating from the Competition
Copying vs Redesigning
Market Data & Source for Parts
Reverse Engineer Existing Parts & Engine Equipment
Enhance Design / System Integration
Manufacturing Development
Validation
Manufacturing & Sourcing
CMM Technology
Computational Fluid Dynamics
Production Qualification Processing
Testing & Producibility
Production
Optical Technology
Durability Analysis
Wax Molding
Structural Analysis
SOAPP Analysis
Finite Element Heat Distribution Analysis
IP Risk Analysis
Materials & Coatings 4
PW Power Systems Design Toolbox: • Multiple Disciplinary Optimization allows for extensive exploration of design options while monitoring many design constraints • Iterations effectiveness maximized
Industrial Gas Turbine Repair Overview PW Power Systems™ IGT repair activities are directed from our San Antonio Center of Excellence. Originally installed as an aero engine repair facility supporting military and commercial customers, this facility is now solely dedicated to IGT repair. The same level of rigor and competency has been extended into the efficient repair of industrial gas turbine components. Each component repair is driven by documented repair procedures, process control and inspection methods, ensuring the highest quality levels. A significant investment in equipment and facility improvements has been made over the last several years as we have transformed this facility into a dedicated industrial gas turbine facility. With that investment in our facility, it will continue to expand our capabilities and retain the best technical talent in the industry. The vast majority of all repair processing required is performed in-house with minimal vendor-supported operations. This helps ensure the highest levels of quality and schedule control. On-site process capabilities include but are not limited to: Elevated Temperature Welding Manual TIG Welding Laser Welding Vacuum Heat Treat Braze Crack Repair CNC Shot Peen Robotic HVOF Plasma Robotic APS Plasma Grit Blast Blending Airflow; Water Flow Digital 450kv X-Ray Heat Tint FPI CMM Bridgeport Machining EDM Plunge and Hole Drill Submerged Ultra-sonic Inspection System FSET (Frequency Scanning Eddy Current Test) System 5-axis CNC Grinding 5
The technical expertise required to develop and execute advanced IGT repairs resides on-site in our San Antonio facility, fortified by the depth and technical resources of over 80 years of turbine engine expertise.
“PWPS has successfully repaired over 650 sets of F-class acomponents.” Gated Repair Process
INDUCT
STRIP & INSPECT
REPAIR
COAT & FINISH
PACK & SHIP
CUSTOMER REVIEW GATE
Strip & Inspect Process Steps
Repair Process Steps
Coat & Finish
Mark ID and Incoming VIS
Machine/Rout Defects
Heat Tint
Photo-Document Incoming
Solution Vacuum Heat Treat
Internal Aluminum Coat
Metallurgical Assessment
FPI
Mask for Coat
Disassembly
Weld Repair
HVOF
X-ray
Blend Repair
Diffusion Vacuum HT
Airflow
Hot Isostatic Press (HIP)
APS TBC Coat
Grit Remove TBC
Machine/CNC
Diffusion and Age Vacuum HT
Chemical or Water-Jet Strip
Vacuum Heat Treat
De-burr Cooling Holes
Heat Tint
EDM Cooling Holes
Heat Tint
Blend Residual Coating
Blend/De-burr
Shot Peen
FPI, Dimensional
Grit Blast Clean
Rail Coat
Photo-Document Post Strip
FPI
Cosmetic Clean
Generate Report
Heat Tint
Airflow; Water Flow
Customer Review Gate
X-ray
X-ray
Airflow
Dimensional Inspect
Water Flow
Final Inspect Visual
Dimensional
Moment Weigh & Sequence
Pre-Coat VIS
Customer Review Gate
Customer Review Gate 6
Standardized Repair Methodology
Engine Types with Repair Experience Frame 7B/7EA
Frame 6FA
Frame 7FA.03
TWP – Technical Work Package
Frame 9FA+e
Frame 9E
V84.2
Technical requirements
V94.2
V84.3A V94.3A2/A4
Defines key characteristics
Router (Traveler) Sequenced operational process steps Piece-by-piece traceability
Work Instructions Instructions for performing a specific type of operation (blending, welding, moment weight, airflow, etc.)
Technique Sheet Detailed parameters and specific instructions within a Work Instruction group unique to a specific operation/ part 7
Coatings State-of-the-Art Coatings Extend Part Life PW Power Systems (PWPS) has created advanced coating systems to refurbish hot section components, provide oxidation/hot-gas-corrosion protection and aid temperature reduction through the use of advanced coating ceramics. These coatings represent state-of-the-art proprietary materials tailored to meet the unique challenges of industrial gas turbine environments.
Engine Models
Blades/ Buckets
Nozzles/ Vanes
Liners
Transition Pieces
Shrouds
Frame 7FA.03
•
•
•
•
•
Frame 6B
•
•
•
Frame 6FA
•
•
•
•
•
Frame 9E
•
V84.3A
•
•
•*
V94.3A2 / A4
•
•
•*
Frame 9FA+e
•
•
•
•
•
*heat shields
8
Aftermarket Field Services PW Power Systems has strategic alliances with best-in-class service providers to deliver the entire portfolio of power plant services, enabling PWPS to deliver the highest quality and most cost-effective maintenance solutions to our customers.
Field Service PWPS offers fully integrated outage services capable of completing emergency, unplanned or scheduled maintenance in a timely, safe, high-quality and costeffective manner. PWPS supports a wide range of power generation equipment including gas turbine, steam turbine, generator and auxiliary equipment. PWPS is ready to provide a highly experienced team to investigate, plan and execute solutions to meet your turbine generator requirements. The PWPS™ objective is to provide total service and support throughout the Americas, Europe, Asia and the Middle East, helping power producers achieve the highest levels of availability, reliability and profit. Turnkey Outage Services
Failure and Root Cause Analysis
Project Management
Outage Parts Kits
Gas/Steam Turbine Minor and Major Inspections
Balance, Tuning and NDE
Generator Inspections
Turbine Control Troubleshooting and Upgrade
Rotor Life Assessments
Remote Monitoring and Diagnostics
Contracted Service Agreements PWPS offers flexible, customizable maintenance agreements to fit your specific requirements. Maintenance objectives have moved from preservation and protection to cost reduction and optimization. Power producers need optimized maintenance solutions to cover the life cycle of the power plant, allowing for: • Risk Management
• Guarantee Performance
• Control Operational Costs
• Technology Advancements
PWPS is an integral part of an ever-changing market continually offering advanced service solutions.
Savannah Machinery Works PW Power Systems works in cooperation with Mitsubishi’s Savannah Machinery Works as a premier service and manufacturing center for gas turbine, steam turbine, and generator refurbishment.
Rotor Refurbishment Mitsubishi’s Savannah facility employs over 350 skilled workers in their 400,000 sq. ft. complex. Located on 121 acres in Savannah, Georgia, this ISO 9001:2008 certified facility manufactures key gas turbine components and provides a comprehensive range of overhaul services, including major rotor refurbishments on advanced, high temperature gas turbines, steam turbines and generators. Savannah Machinery Works is dedicated to maximizing availability, reliability, and profitability for power providers. 9
The export is made under the authority of “No License Required” (NLR). ECCN EAR99 No SED required per 30.55(h) FTSR. These commodities, technology, or software were exported from the United States in accordance with the Export Administration Regulations. Diversion contrary to U.S. Law prohibited. Copyright © 2014 PW Power Systems, Inc. PW is a trademark of United Technologies Corporation. Used with permission. Pratt & Whitney is a trademark of United Technologies Corporation. Used with permission.
PW Power Systems, Inc. 628 Hebron Avenue, Suite 400 Glastonbury, CT 06033 www.pwps.com
IGT_DIG_012014 01/2014
Industrial Gas Turbines Aftermarket Parts, Repairs & Services
1 About Us 2 Industrial Gas Turbine New Parts 6 Industrial Gas Turbine Repair 9 Aftermarket Field Services
About Us PW Power Systems, Inc. (PWPS) is a world leader in developing and manufacturing energy solutions for power generation offering products for aero-derivative and industrial gas turbines. PWPS™ offers a full range of maintenance, overhaul, repair and spare parts for other manufacturers’ gas turbines with specific concentration on the high-temperature “F” class industrial machines. PWPS also offers quick turnaround for parts and repair services utilizing the latest in component repair technology integrated from Pratt & Whitney® Global Aftermarket Service expertise. PW Power Systems is committed to providing high-quality solutions for the distributed energy market that increase energy productivity, energy reliability, and operational savings for our customers.
1
Industrial Gas Turbine New Parts PW Power Systems designs, reengineers and manufactures components for use in land-based Industrial Gas Turbine (IGT) applications. As part of the portfolio of components and services available, PWPS produces and repairs replacement parts for the hot gas path (HGP) from other OEMs of large-frame gas turbines. The PWPS™ components are manufactured using Pratt & Whitney® proprietary alloys and coatings. These materials, coupled with aerospace and industrial design technology and quality systems, enable users to install these components and operate their equipment with no degradation in machine performance while realizing improved durability of the hot gas path components. PWPS™ solutions allow customers to develop a degree of confidence that is unparalleled in the industry. 2
PWPS experience with HGP parts and repairs is based on comparisons of distress modes observed in the fleet. At PW Power Systems, it is our goal to provide value- based gas turbine solutions for our customers by incorporating customer feedback, component optimization and the advantage of over 80 years of technology development from our extensive hightemperature aviation heritage. PWPS is leveraging Pratt & Whitney® world-renowned hot section engineering to address the needs of the industrial gas turbine customer. PWPS has an extensive proven history of producing industry-leading technological solutions. We utilize this advantage by applying our proprietary technology to create new and innovative solutions for our industrial customers.
Engineering Standard Work The Foundation for Quality OEM Part
Industrial Gas Turbine Enhanced New Parts
Scanned Data
Scanning
Initial CAD Model
Systems & Aero Analysis
Advanced Proprietary Technology includes: • High-Temperature Technology • Proprietary Alloys • Metallic Coatings • Ceramic Coatings • Film Cooling • Multidisciplinary Optimization • Tip Clearance Material Systems • Advanced Computational Modeling Techniques
60 HZ Portfolio offering
Design/Analysis Multi-disciplinary Optimization
• Frame 7FA.03 1st, 2nd and 3rd Stage Buckets, Nozzles & Shroud Blocks • Frame 7FA.03 DLN 2.6 Transition Pieces, Liners, Flow Sleeves, Liner End Cap, Fuel Nozzles • Frame 7EA 1st, 2nd and 3rd Stage Bucket
50 HZ Portfolio offering HighTemperature-Class hardware
Final Definition
• STG5-4000F (V94.3A4x) Hot Gas Path Components • 1st, 2nd, 3rd, 4th Stage Blades & Vanes • Blade Outer Air Seals (BOAS) New PWPS™ Part
“PWPS has surpassed over 1.8 million hours of accumulated run time on its Frame 7FA.03 (7FA+e) HGP components.” 3
Product Development Process Robust intellectual property strategy integrated into reengineering design
Project Launch
Engineering Analysis
Prelim IP Assessment
Detailed Design
Preliminary Design
Metrology
Production
Features List
IP Risk Identification
Final Clearance
IP Due Diligence Process
PW Power Systems™ Experience and Technology Differentiating from the Competition
Copying vs Redesigning
Market Data & Source for Parts
Reverse Engineer Existing Parts & Engine Equipment
Enhance Design / System Integration
Manufacturing Development
Validation
Manufacturing & Sourcing
CMM Technology
Computational Fluid Dynamics
Production Qualification Processing
Testing & Producibility
Production
Optical Technology
Durability Analysis
Wax Molding
Structural Analysis
SOAPP Analysis
Finite Element Heat Distribution Analysis
IP Risk Analysis
Materials & Coatings 4
PW Power Systems Design Toolbox: • Multiple Disciplinary Optimization allows for extensive exploration of design options while monitoring many design constraints • Iterations effectiveness maximized
Industrial Gas Turbine Repair Overview PW Power Systems™ IGT repair activities are directed from our San Antonio Center of Excellence. Originally installed as an aero engine repair facility supporting military and commercial customers, this facility is now solely dedicated to IGT repair. The same level of rigor and competency has been extended into the efficient repair of industrial gas turbine components. Each component repair is driven by documented repair procedures, process control and inspection methods, ensuring the highest quality levels. A significant investment in equipment and facility improvements has been made over the last several years as we have transformed this facility into a dedicated industrial gas turbine facility. With that investment in our facility, it will continue to expand our capabilities and retain the best technical talent in the industry. The vast majority of all repair processing required is performed in-house with minimal vendor-supported operations. This helps ensure the highest levels of quality and schedule control. On-site process capabilities include but are not limited to: Elevated Temperature Welding Manual TIG Welding Laser Welding Vacuum Heat Treat Braze Crack Repair CNC Shot Peen Robotic HVOF Plasma Robotic APS Plasma Grit Blast Blending Airflow; Water Flow Digital 450kv X-Ray Heat Tint FPI CMM Bridgeport Machining EDM Plunge and Hole Drill Submerged Ultra-sonic Inspection System FSET (Frequency Scanning Eddy Current Test) System 5-axis CNC Grinding 5
The technical expertise required to develop and execute advanced IGT repairs resides on-site in our San Antonio facility, fortified by the depth and technical resources of over 80 years of turbine engine expertise.
“PWPS has successfully repaired over 650 sets of F-class acomponents.” Gated Repair Process
INDUCT
STRIP & INSPECT
REPAIR
COAT & FINISH
PACK & SHIP
CUSTOMER REVIEW GATE
Strip & Inspect Process Steps
Repair Process Steps
Coat & Finish
Mark ID and Incoming VIS
Machine/Rout Defects
Heat Tint
Photo-Document Incoming
Solution Vacuum Heat Treat
Internal Aluminum Coat
Metallurgical Assessment
FPI
Mask for Coat
Disassembly
Weld Repair
HVOF
X-ray
Blend Repair
Diffusion Vacuum HT
Airflow
Hot Isostatic Press (HIP)
APS TBC Coat
Grit Remove TBC
Machine/CNC
Diffusion and Age Vacuum HT
Chemical or Water-Jet Strip
Vacuum Heat Treat
De-burr Cooling Holes
Heat Tint
EDM Cooling Holes
Heat Tint
Blend Residual Coating
Blend/De-burr
Shot Peen
FPI, Dimensional
Grit Blast Clean
Rail Coat
Photo-Document Post Strip
FPI
Cosmetic Clean
Generate Report
Heat Tint
Airflow; Water Flow
Customer Review Gate
X-ray
X-ray
Airflow
Dimensional Inspect
Water Flow
Final Inspect Visual
Dimensional
Moment Weigh & Sequence
Pre-Coat VIS
Customer Review Gate
Customer Review Gate 6
Standardized Repair Methodology
Engine Types with Repair Experience Frame 7B/7EA
Frame 6FA
Frame 7FA.03
TWP – Technical Work Package
Frame 9FA+e
Frame 9E
V84.2
Technical requirements
V94.2
V84.3A V94.3A2/A4
Defines key characteristics
Router (Traveler) Sequenced operational process steps Piece-by-piece traceability
Work Instructions Instructions for performing a specific type of operation (blending, welding, moment weight, airflow, etc.)
Technique Sheet Detailed parameters and specific instructions within a Work Instruction group unique to a specific operation/ part 7
Coatings State-of-the-Art Coatings Extend Part Life PW Power Systems (PWPS) has created advanced coating systems to refurbish hot section components, provide oxidation/hot-gas-corrosion protection and aid temperature reduction through the use of advanced coating ceramics. These coatings represent state-of-the-art proprietary materials tailored to meet the unique challenges of industrial gas turbine environments.
Engine Models
Blades/ Buckets
Nozzles/ Vanes
Liners
Transition Pieces
Shrouds
Frame 7FA.03
•
•
•
•
•
Frame 6B
•
•
•
Frame 6FA
•
•
•
•
•
Frame 9E
•
V84.3A
•
•
•*
V94.3A2 / A4
•
•
•*
Frame 9FA+e
•
•
•
•
•
*heat shields
8
Aftermarket Field Services PW Power Systems has strategic alliances with best-in-class service providers to deliver the entire portfolio of power plant services, enabling PWPS to deliver the highest quality and most cost-effective maintenance solutions to our customers.
Field Service PWPS offers fully integrated outage services capable of completing emergency, unplanned or scheduled maintenance in a timely, safe, high-quality and costeffective manner. PWPS supports a wide range of power generation equipment including gas turbine, steam turbine, generator and auxiliary equipment. PWPS is ready to provide a highly experienced team to investigate, plan and execute solutions to meet your turbine generator requirements. The PWPS™ objective is to provide total service and support throughout the Americas, Europe, Asia and the Middle East, helping power producers achieve the highest levels of availability, reliability and profit. Turnkey Outage Services
Failure and Root Cause Analysis
Project Management
Outage Parts Kits
Gas/Steam Turbine Minor and Major Inspections
Balance, Tuning and NDE
Generator Inspections
Turbine Control Troubleshooting and Upgrade
Rotor Life Assessments
Remote Monitoring and Diagnostics
Contracted Service Agreements PWPS offers flexible, customizable maintenance agreements to fit your specific requirements. Maintenance objectives have moved from preservation and protection to cost reduction and optimization. Power producers need optimized maintenance solutions to cover the life cycle of the power plant, allowing for: • Risk Management
• Guarantee Performance
• Control Operational Costs
• Technology Advancements
PWPS is an integral part of an ever-changing market continually offering advanced service solutions.
Savannah Machinery Works PW Power Systems works in cooperation with Mitsubishi’s Savannah Machinery Works as a premier service and manufacturing center for gas turbine, steam turbine, and generator refurbishment.
Rotor Refurbishment Mitsubishi’s Savannah facility employs over 350 skilled workers in their 400,000 sq. ft. complex. Located on 121 acres in Savannah, Georgia, this ISO 9001:2008 certified facility manufactures key gas turbine components and provides a comprehensive range of overhaul services, including major rotor refurbishments on advanced, high temperature gas turbines, steam turbines and generators. Savannah Machinery Works is dedicated to maximizing availability, reliability, and profitability for power providers. 9
The export is made under the authority of “No License Required” (NLR). ECCN EAR99 No SED required per 30.55(h) FTSR. These commodities, technology, or software were exported from the United States in accordance with the Export Administration Regulations. Diversion contrary to U.S. Law prohibited. Copyright © 2014 PW Power Systems, Inc. PW is a trademark of United Technologies Corporation. Used with permission. Pratt & Whitney is a trademark of United Technologies Corporation. Used with permission.
PW Power Systems, Inc. 628 Hebron Avenue, Suite 400 Glastonbury, CT 06033 www.pwps.com
IGT_DIG_012014 01/2014
